Research And Development Process Engineer Jobs in McAllen, TX

Job Summary

Responsible for creating, supporting, and developing new and existing process designs related to manufacturing and fabrication processes. This is successfully accomplished by understanding, accurately specifying, and adhering to customer requirements, utilizing and applying quality tools and methods and pursuing continuous improvement in all aspects of product and process design. These efforts will have a direct impact on reducing labor and material costs, while improving value, reliability, and performance. The associate will plan and manage process and product related design and validation activities.

This position is a first shift, full-time position that reports to the Senior Manufacturing Manager.

Job Duties

Methods Improvement 35%

Conduct work measurement studies to determine overall equipment effectiveness using Industrial Engineering techniques such as stopwatch studies, work sampling, ratio-delay, predetermined times, and video tape-recording, in conducting studies for work measurement

Work with manufacturing engineers and product development engineers to create/develop manufacturing and fabrication methods for new or revised products

Evaluate all possible methods and determine optimal method that provides least cost, most efficient and safe methods to be used

Document methods with clear, well-written methods descriptions including photographs where applicable

Maintain departmental records on work measurement activity including standard numbers, department assigned, operation numbers, standard description, effective data, and quantity per year, net increase/decrease

Review work methods to assure that operations are being performed in a safe, efficient manner. Work with supervisors and group leaders to improve methods as necessary

Design new fixtures and equipment to facility process improvements

Manage multiple capital projects from selection through implementation

Problem Solving and Quality Improvement 30%

Maintain an effective audit program for feedback to production managers, engineering, and quality assurance

Communicate how well process specifications are being followed, the capability of controlling process variables, and the maintenance condition of the equipment

Provide technical service to all departments to resolve quality related problems

Assist in the training and education of hourly, supervisory and management associates as required

Work with current suppliers to develop and improve existing products and processes, striving to reduce cost and minimize waste

Develop and maintain process control testing procedures for work-in-process to eliminate any off-quality performance

Product and Process Specifications 10%

Develop and maintain process specifications to produce the highest level of quality throughout the entire component manufacturing / fabrication / assembly process

Determine the optimum process routing for components and products, producing the highest quality levels at the lowest cost and minimizing waste

Develop written procedures in the form of Standard Practice Instructions to specifically describe how to perform a required task and steps and tools necessary to complete that task

Establish procedures and systems to prevent the production of off-quality products

Establish approval systems as a means of controlling process conditions, fabric routings, standard practices, and documentation of completed work assignments

Provide the cost accounting department and the industrial engineering department with necessary information to determine product costs and departmental cost standards

 New Product Introduction 10%

Work with product development engineers to determine the optimum process routing and conditions for new products

Assist product development engineers in monitoring the quality and manufacturability of components and finished product in each production department

Work with facilities planning to define plant space needs concerning equipment and its functionality

Conduct plant evaluations of new equipment to determine performance levels in the areas of quality, safety, maintenance and cost

Prior to starting up a newly installed piece of equipment, work with manufacturing engineering, provide a safety inspection, and provide preliminary operating conditions to the production area

Work with suppliers in developing and improving new products and processes while reducing costs

Coordinate trials and evaluations of new products to ensure manufacturability, quality, and performance

Document results

Production Layout 10%

Develop layouts utilizing the following lean manufacturing principles:

• Set-up time reduction
• Visual management
• Kanban/pull systems
• One-piece flow
• Value stream mapping
• Cellular Manufacturing

Investigate activity-machine-relationship as a basis for machine, operations, department or plant-wide layout

Using activity relationship information provide layouts of work areas, departments, facilities and plants

Provide copies of layouts to management personnel and others as required

Conduct discussions, engages production associates, departmental manager, and other engineering members for all layout changes

Administration and Other 5%

Document in writing all projects, studies, and work assignments and outcomes to provide accurate and complete information for future reference

Stay abreast of all current and new technology in industry

Review trade magazines and periodicals, attend technical conferences, and meet with supplier technical reps

Continuously work toward automating manufacturing processes and monitoring results through automation

As required, maintain records in an orderly fashion and analyze production and/or quality data as appropriate

Provide regular reports to stakeholders as appropriate

Quality  - Integrates quality at the source thinking and activities in daily, individual, team and project work. (Applies to all job duties 100%)

Utilizes quality/process tools and methodology in daily individual work

Utilizes quality/process tools and methodology on teams

Defines and documents individual processes within sphere of control

Ensures that others are trained as back-ups on (processes) within the area/department

Improves processes within sphere of control

Identifies waste and rework and enacts plan to improve/solve

Checks satisfaction of internal customers through use of quality tools and Customer/Supplier metrics

Education and Experience

Bachelor's degree in Mechanical Engineering, Industrial Engineering, or Manufacturing Engineering

Minimum of 3 years with strong industrial experience as a Process Engineer

Minimum of 7 years of practical manufacturing and engineering experience in designing and improving manufacturing processes

Capital project management experience

Knowledge, Skills, and Abilities

Data collection and management of database

Technical writing skills for memos, lab reports, and project updates

Strong general math skills (add, subtract, multiply, divide, percentages, fractions, metric conversions, algebra, and geometry)

Good interpersonal skills

Good analytical and problem solving skills including statistical analysis

Good communication skills (verbal, written)

Technical Writing

Experience with automation and digitalization

General computer skills Excel, MS Word, Outlook, MS Project and Access

Preparing Samples for Testing and Analysis

Familiarity with Springs products and processes

In depth knowledge of various manufacturing processes

Manage work according to established project timelines

Knowledge and application of engineering principles

Strong software skills in spreadsheets, word processing, presentation software, and CAD

Mechanical aptitude and dexterity is required to work around machines safely and effectively

Creativity is required to develop new processes and solutions in a timely fashion

Must be experienced with continuous improvement methodologies such as Toyota Production System (TPS), Lean Manufacturing, and Six Sigma

Must be flexible with job assignments, able to work independently and well with others (team environment)

Must be organized, methodical, and handle multiple tasks simultaneously

Must manage multiple medium or large scope projects

Must properly document results of test procedures

Physical Requirements

Ability to sit, stand and walk for 8 hours 

Ability to lift 25 pounds occasionally

The annual base/hourly wage for this position is reasonably expected to be $91k/year.  Factors which may affect starting pay may include geography/market, skills, education, experience and other qualifications of the successful candidate.

This position is eligible for an annual bonus as well of up to 5%.  

Benefits: The Company offers the following benefits for this position, subject to applicable eligibility requirements: medical insurance, dental insurance,  vision insurance, 401(k) retirement plan with up to 5% company match of eligible contributions, life insurance, long-term disability insurance, short-term disability insurance, paid sick time at an amount that meets or exceeds all local requirements, paid vacation time (pro-rated for 2025 based on start date), eleven paid holidays per year, and one paid volunteer day off per year.