Process Engineer – Cutting, Lead Preparation & Tooling

About the role

The Cutting, Lead Preparation, Process & Tooling Engineer will define, develop and optimise manufacturing processes and equipment for cutting, stripping, crimping and lead preparation at Lear's Kenitra plant. The role ensures that all production means are ready for new launches and serial production while supporting continuous improvement and cost‑efficiency goals.

Key responsibilities

• Define cutting, lead preparation and crimping process requirements (machines, parameters, tooling) for new projects and engineering changes.
• Plan and coordinate the availability of cutting machines, applicators, tooling and equipment at SOP through supplier follow‑up and inter‑plant collaboration.
• Lead acquisition, installation, validation and ramp‑up of equipment and tooling according to project timelines.
• Prepare and manage CAPEX requests for tooling and equipment, ensuring cost control and budget adherence.
• Optimise manufacturing processes by defining cycle times, improving methods and balancing production lines.
• Drive continuous‑improvement actions on quality, productivity and cost using Lean tools such as Value Stream Mapping, SIPOC and Kaizen.
• Coordinate industrialisation activities with production, maintenance, quality, central engineering, suppliers and customers.
• Develop and maintain process and tooling documentation, including work instructions, standards and technical files.
• Monitor tooling and equipment performance, capacity and inventory status to ensure readiness and reliability.
• Conduct capacity studies and support production planning with accurate data and analysis.

Required profile

• Proven experience in defining and optimising manufacturing processes, especially cutting, stripping, crimping and lead preparation.
• Ability to manage equipment acquisition, validation, ramp‑up and CAPEX budgeting.
• Familiarity with Lean improvement methodologies (Value Stream Mapping, SIPOC, Kaizen).
• Strong coordination skills across production, maintenance, quality, engineering, suppliers and customers.
• Experience in creating and maintaining technical documentation and conducting capacity analyses.

Required skills

• Cutting process engineering
• Lead preparation
• Crimping process
• Equipment acquisition and validation
• CAPEX management
• Lean tools (Value Stream Mapping, SIPOC, Kaizen)
• Process documentation
• Capacity analysis