1. Position Summary
The Senior Process Engineer is responsible for leading complex process development, optimization, and continuous improvement initiatives across manufacturing operations. This role provides technical leadership and guidance to junior engineers and project teams while driving long-term strategic improvements in product quality, efficiency, and cost-effectiveness. The Senior Process Engineer works cross-functionally with engineering, operations, quality, and supply chain teams to execute projects and initiatives aligned with business goals.
2. Essential Job Duties
- Lead complex cross-functional projects and act as the technical lead on major process development initiatives.
- Mentor and provide technical guidance to Process Engineers and technical staff.
- Evaluate and implement emerging technologies and advanced manufacturing methods.
- Lead root cause analysis and corrective action planning for high-impact process issues.
- Develop and optimize process strategies and standards for new and existing products.
- Drive implementation of Lean Manufacturing and Six Sigma methodologies.
- Create and manage strategic process improvement roadmaps.
- Develop and present technical reports, proposals, and cost-benefit analyses to leadership.
- Coordinate APQP activities and support PPAP documentation.
- Support internal and external audits and act as process subject matter expert.
- Collaborate with design and tooling engineers to influence product manufacturability.
- Participate in and lead capital project planning and justification.
- Maintain and improve process documentation and engineering change systems.
- Stay informed on industry trends, new equipment, and best practices.
- Provide high-level technical support to manufacturing teams across locations.
- 10% / occasional travel to other manufacturing or supplier sites may be required
- All other tasks and duties as assigned by manager.
3. Skills and Competencies
- Advanced analytical and problem-solving skills; expert-level statistical analysis and DOE.
- Strong leadership and mentoring capabilities.
- Excellent written and verbal communication skills, including presentation to senior leaders.
- Strategic thinking and ability to align technical decisions with business goals.
- Proficiency in Microsoft Office, Minitab, SolidWorks, AutoCAD, and manufacturing software.
- Expertise in Lean Manufacturing, Six Sigma, APQP, and continuous improvement frameworks.
- Expert proficiency in interpreting and analyzing complex technical documentation, including advanced blueprints, GD&T, and engineering specifications
- Ability to influence and collaborate across departments without direct authority.
4. Education and Experience
- Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, or a related field is required.
- 5–8 years of experience in a manufacturing environment.
- Experience in powdered metal or related industries strongly preferred.
- Working knowledge of APQP and PPAP processes.
- Advanced certifications such as Six Sigma Black Belt or PMP are highly desirable.
5. Physical Demands
- Frequent walking, standing, and sitting in both office and plant environments.
- Occasional lifting of up to 35 pounds.
- Use of PPE including safety glasses, gloves, and hearing protection as required.
- Visual acuity and manual dexterity for inspection and data analysis.
6. Safety Requirements
- Comply with all company safety policies and procedures.
- Lead and participate in safety initiatives and hazard assessments.
- Ensure proper use of PPE and promote best safety practices across teams.
- Actively contribute to maintaining a safe, clean, and compliant work environment.
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