Sr Process Engineer, DU

Role Overview

Sr Manufacturing Engineer, Drive Unit at Lucid Motors. This role owns process engineering for an assigned section of the DU assembly line at AMP-2, covering rotor/stator, gearbox integration, HV wiring, or EOL test. The engineer joins at facility launch and builds process documentation, PFMEA, control plans, and process capability studies from first commissioning through volume ramp-up.

Company Overview

Lucid Motors creates exceptional mobility experiences through innovation and proprietary technology. The company designs, engineers, and manufactures vehicles in-house across global offices and manufacturing facilities. Teams are united by a shared commitment to excellence and refuse to compromise between performance and sustainability, design and engineering, or ambition and integrity.

Role Purpose

Own process engineering accountability for an assigned DU assembly line section through facility launch and volume ramp-up, delivering first-pass yield, process capability, and scrap performance while building structured technical ownership transfer to the Saudi workforce.

Key Responsibilities

DU Process Engineering

• Own process engineering for an assigned DU line section.
• Develop and maintain Process Flow Diagrams (PFDs), control plans, Standard Work Instructions (SWIs), and set-up standards.
• Lead process trials, pilot builds, and first-off-tool events for assigned area.

Process Capability & FPY Improvement

• Own Cpk/Ppk and FPY performance for assigned processes.
• Deploy Design of Experiments (DoE) and structured problem-solving on chronic losses.
• Maintain Statistical Process Control (SPC) monitoring and closed-loop process control.

PFMEA & Control Plans

• Maintain PFMEA registers and Control Plans for all related robots and cell operations.
• Implement poka-yoke and mistake-proofing in robotics cells.

Equipment & Tooling Support

• Support Maintenance and Automation on equipment issues affecting process performance.
• Own tooling design reviews, gauge design, and process fixtures for assigned area.

Scrap & Cost Reduction

• Own scrap reduction roadmap for assigned area and robotics-related scrap.
• Drive cost-per-unit improvement through cycle time, yield, and labor efficiency.

TPM & Autonomous Maintenance Support

• Support Total Productive Maintenance (TPM) deployment across Autonomous Maintenance, Planned Maintenance, and Focused Improvement pillars.
• Contribute to equipment Overall Equipment Effectiveness (OEE) improvement, Mean Time Between Failures (MTBF) and Mean Time To Repair (MTTR) reduction, and predictive maintenance strategies.
• Leverage Manufacturing Execution System (MES), Industrial Internet of Things (IIoT), and historian analytics to identify and eliminate losses.

HV Safety & Compliance

• Enforce High Voltage (HV) Lockout-Tagout (LOTO), HV Interlock Loop (HVIL) continuity, and mandatory HV Personal Protective Equipment (PPE) for all work on or near EV Powertrain equipment.
• Comply with SASO, Saudi Ministry of Labor, IEC 60204, and functional safety standards (ISO 13849 / IEC 62061).
• Support HV emergency response including thermal runaway isolation and battery-related incident procedures.
• Achieve and maintain HV safety competency appropriate to scope of work.

Launch Governance & Ramp-Up

• Support AMP-2 Safe Launch activities, run-at-rate events, and capacity verification within scope.
• Contribute to Launch Readiness Reviews, Layered Process Audits, and Process Confirmation routines.
• Participate in Quality-Rapid-Response-Cell (QRQC) and Root Cause Corrective Action (RCCA) escalations during launch and ramp-up phases.

APQP, Equipment Acceptance & Process Control

• Maintain coherent PFD, PFMEA, Control Plan, SWI, process specifications, reaction plans, and change records for assigned DU processes.
• Lead Measurement System Analysis (MSA), capability, run-at-rate, Production Part Approval Process (PPAP) / Production Sample Warrant (PSW), and first-off-tool evidence; define production-release criteria and deviation controls.
• Develop process windows and error-proofing for precision fastening, pressing, dispensing, leak test, electrical test, Noise-Vibration-Harshness (NVH), and traceability interfaces.
• Use DoE, SPC, and correlation to improve FPY/Cpk and eliminate scrap, rework, cycle, and warranty risk.

Launch Governance, Change Control & Operational Readiness

• Support Factory Acceptance Test (FAT), Site Acceptance Test (SAT), commissioning, equipment acceptance, Safe Launch, run-at-rate, and capacity verification with objective evidence and disciplined punch-list closure.
• Control production, process, software, and test changes through documented risk assessment, approvals, validation, revision history, and rollback or containment planning.
• Participate in readiness reviews, Layered Process Audits, Process Confirmation, and QRQC/RCCA; close assigned actions with verified effectiveness.

Safety, Quality, Data Integrity & Compliance

• Apply role-specific HV LOTO/HVIL, machine safety, stored-energy isolation, electrical safe-work, and PPE requirements; never bypass safety devices or product protections.
• Protect product genealogy, calibrated-tool status, test/measurement integrity, document control, and audit-ready objective evidence.
• Comply with applicable AMP-2, SASO, Saudi labor/EHS, IATF 16949, IEC 60204, and functional-safety requirements within assigned scope.

Saudization, Capability Transfer & Collaboration

• Build Saudi national capability through structured On-The-Job-Training (OJT), Individual Learning Units (ILU), skills matrices, practical assessment, certification, cross-training, mentorship, and documented knowledge transfer.
• Create technical standards, troubleshooting guides, and training material.
• Collaborate across Production, Quality, Maintenance, Automation/Robotics, Manufacturing Engineering, Environmental Health & Safety (EHS), Information Technology/Operational Technology (IT/OT), MES, Supply Chain, Product Engineering, and suppliers.

Qualifications & Experience

• Bachelor's degree in Mechanical, Electrical, or Mechatronics Engineering.
• 5 to 8 years in EV or advanced automotive manufacturing.
• 3+ years in E-motors manufacturing.
• Demonstrated PFMEA, PPAP, and SPC track record.
• Demonstrated experience with commissioning, FAT/SAT, launch, production readiness, or high-volume manufacturing ramp within the role discipline.
• Six Sigma Green Belt or Black Belt certification.
• Greenfield launch experience.
• IATF 16949 knowledge and compliance.
• Working knowledge of machine safety, HV safety, and traceability requirements applicable to the role.
• Preferred: Recognized discipline certification, Lean/Six Sigma certification, greenfield EV/automotive launch experience, and Kingdom of Saudi Arabia (KSA) workforce-development experience.

Skills & Competencies

• PFMEA, Control Plan, SPC, and PPAP fluency.
• Design of Experiments (DoE) and structured problem-solving capability.
• Effective cross-functional communicator across Quality, Maintenance, Automation, and Production.
• Hands-on execution mindset in greenfield contexts.
• Technical standards development, structured problem-solving, risk-based decision-making, and controlled documentation.
• Data literacy: KPI definition, trend analysis, evidence-based validation, and clear executive and shop-floor communication.
• Cross-functional influence, supplier coordination, and disciplined ownership in a greenfield launch environment.
• Coaching, competency assessment, and knowledge transfer in a multicultural workplace.
• Fluent in English; Arabic strongly preferred.

Additional Information

Compensation & Benefits

• Medical, dental, and vision insurance.
• Life and disability coverage.
• Paid time off: Hourly/non-exempt employees accrue up to 120 hours; salaried/exempt employees accrue up to 160 hours.
• Paid holidays and paid sick leave.
• 401(k) retirement plan.
• Eligible employees may participate in Lucid's equity program and/or discretionary annual cash incentive program.
• Incentive and equity awards are determined based on individual performance, role scope, market considerations, and overall company results, in accordance with applicable plan terms.

Equal Opportunity & Accessibility

• Lucid Motors is an equal opportunity employer committed to providing an inclusive