Process Development Engineer at Toly Group in Zejtun, Malta

Process Development Engineer

Location: Zejtun, Malta

We are looking for a highly motivated Process Development Engineer to join our Development team. This role is responsible for the development, optimization, and validation of manufacturing processes for new products. The successful candidate will play a key role in ensuring robust, capable, and customer-approved manufacturing processes that consistently meet quality, cost, and delivery expectations.

This position requires strong analytical skills, hands-on engineering expertise, and the ability to collaborate across multiple functions, including Project Management, Quality, Production, and customers.

Key Responsibilities

• Develop, optimize, and validate individual manufacturing processes for new products entering production.
• Conduct PFMEA (Process Failure Mode and Effects Analysis) and integrate risk mitigation actions into process and layout design.
• Ensure corrective and preventive actions are effectively implemented and sustained.
• Define optimal process windows through Design of Experiments (DOE), capability studies, and engineering analysis.
• Lead the development of internal manufacturing processes.
• Define and validate processing parameters for welding, decoration, lacquering, assembly, and other manufacturing operations.
• Validate customer artwork requirements and coordinate the procurement of decoration materials and product-specific equipment.
• Specify and order equipment required for production processes
• Analyze trial data generated during process development and refine parameters to ensure product specifications and customer requirements are consistently achieved.
• Maintain and update product specifications with validated process parameters.
• Coordinate process validation activities and ensure all validation requirements are successfully completed.
• Prepare Pre-Production Samples (PPS) and associated documentation for customer approval.
• Present validation parts to Quality for final process validation and investigate any validation failures.
• Collaborate with Quality, Production, Tooling, and Project teams to implement solutions for process-related issues.
• Ensure all products and processes are fully validated and approved before production launch.

Qualifications & Experience

• Bachelor's Degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, or a related technical discipline.
• Experience in process development, manufacturing engineering, or new product introduction within a manufacturing environment.
• Strong knowledge of PFMEA, DOE, process validation, capability studies, and statistical analysis techniques.
• Experience with customer approval processes such as PPS, PPAP, or equivalent submission requirements.
• Familiarity with welding, assembly, decoration, lacquering, or similar manufacturing technologies is considered an asset.
• Ability to analyze technical data and make evidence-based decisions.
• Strong problem-solving, project management, and organizational skills.
• Excellent communication and stakeholder management skills.
• Proficiency in Microsoft Office and engineering-related software tools.