Senior Process Development Engineer Jobs in Connecticut

Position Description

Sr Process Engineer - CNC

Purpose
This position supports the Motors Business Unit by handling manufacturing engineering tasks, including creating and maintaining bills of manufacture in the ERP system, designing and sourcing tooling, reviewing drawings for manufacturability, CNC programming, and improving internal manufacturing processes.

Key Responsibilities

Manufacturing Support

• Create and maintain bills of manufacture (engineering masters) in the Visual ERP system.
• Design tools and fixtures, working with logistics to manage in-house or external manufacturing.
• Troubleshoot shop floor issues by collaborating with manufacturing, QA, logistics, and engineering teams.
• Handle Non-Conforming Materials (NCM) from both in-house production and external suppliers.
• Specify and document manufacturing processes to ensure successful part production.
• Review Engineering Change Notices (ECNs) and update engineering masters and work orders as needed.
• Research and recommend equipment to meet production and safety requirements.
• Plan and optimize new part processes in collaboration with the CNC manufacturing team.
• Maximize machine efficiency and uptime, aiming for a 90% Overall Equipment Effectiveness (OEE). Collect and analyze machine data to identify areas for improvement.
• Use SolidWorks to create operation-level drawings and prints.
• Read and interpret blueprints using ASME Y14.5 GD&T.
• Troubleshoot and resolve manufacturing issues at both the component and assembly levels.
• Develop work instructions and support Quality Management Systems (QMS).
• Assist with estimating labor and material costs for new and existing products.
• Work with CNC and maintenance teams to troubleshoot machine issues and improve performance.
• Make program adjustments in Esprit and write programs when necessary
• Lead new product integration efforts in the machine shop

Process Development

• Develop efficient manufacturing processes, incorporating fail-safe in-process inspection methods.
• Design fixtures for both new and existing parts, ensuring optimal manufacturability.
• Create operation sheets and define Key Control Indicators (KCIs) for production processes.
• Set up and program complex jobs on 5-axis CNC machines.
• Leverage Esprit CAM software for CNC programming.

Collaboration and Communication

• Suppliers: Ensure external tooling and fixtures meet specifications and support production needs.
• Sales: Provide technical input on RFQs and customer-related inquiries.
• Engineering: Collaborate on designs, tooling, testing, and rework recommendations, particularly during new product development.
• Quality Assurance: Partner with QA to review inspection methods and external supplier processes.
• Manufacturing: Work with production teams to resolve issues related to routing, tooling, raw materials, and shop floor processes.
• Materials & Sourcing: Assist purchasing with decisions on in-house production versus external sourcing.

Continuous Improvement

• Participate in Continuous Improvement Task Teams to refine manufacturing processes.
• Apply new technologies and best practices to reduce production costs.
• Conduct time studies to optimize labor and improve productivity.

• Provide updates and communicate progress or challenges to team leaders.

Physical & Safety Requirements

• Split time between office (50%) and shop floor (50%).
• Wear required personal protective equipment (PPE), including safety glasses, when on the shop floor.
• Occasionally lift to 50 pounds and work near operating machinery.
• Travel to vendor locations for audits or process qualifications as needed.

Training & Development

• Attend relevant training to stay updated on industry trends and improve job performance.
• Assist in training new engineers to ensure smooth transitions and role progression.

Qualifications

• Extensive machining experience preferred
• Experience with CAD software, particularly SolidWorks.
• Strong understanding of machining processes and best practices.
• Familiarity with rotating machines is a plus.
• Proficiency in Microsoft Word and Excel.
• Solid understanding of engineering drawings and GD&T principles.
• Excellent communication and teamwork skills.
• Experience with ISO standards and Lean Manufacturing (Six Sigma, Kaizen, Kanban, 5S) is a bonus.
• Willingness to travel domestically

Accountability

Reports to the Motors Engineering Manager. Ensures that all work is done in accordance with internal and external customer specifications and company policy. Informs Motors Engineering team and ensures awareness of all progress and problems.

Physical & Safety Requirements

Job requires sitting at a desk doing normal office work, including phone communications and using a computer. Also involves standing and walking in an office and a manufacturing facility.

• Spends roughly 50% of time working at a desk in a normal office environment.
• Spends roughly 50% of time working on the shop floor
• Must wear eye protection and any other required personal protective equipment while on the shop floor.
• Visits vendors for process qualification and/ or audit, on an as needed basis.

Training / Cross Training / Progression

Attend job related training to support job function and production requirements. Assists in the training of new Manufacturing Engineers for this position to promote orderly progression.