Senior Process Development Engineer Jobs in Milwaukee, WI

Milwaukee Electronics is seeking a hands-on Senior Manufacturing Engineer to lead complex electronic products from early manufacturing review and New Product Introduction through launch and full production at our Milwaukee facility. In this influential role, you will shape manufacturing processes, tooling, documentation, and technical decisions while solving real production challenges across SMT, mechanical assembly, and test operations. If you enjoy taking ownership, collaborating across teams, and seeing your engineering work come to life on the production floor, this is an opportunity to make a meaningful impact on both new programs and existing operations.

SUMMARY

The Senior Manufacturing Engineer leads projects, process development and launch support for electronic assemblies from New Product Introduction (NPI) through full production, working across SMT, mechanical assembly, and test operations. This role owns the manufacturing readiness of new programs and continuous improvement of current production, including designing and validating tooling and fixtures, developing process documentation, and driving root-cause problem solving on the production floor. The Senior Manufacturing Engineer will partner closely with Program Management, Quality, Supply Chain, and Customer Engineering to deliver builds on time and to spec. The Senior Manufacturing Engineer exercises independent technical judgment on process and tooling decisions and serves as an escalation point for production and process issues.

ESSENTIAL DUTIES AND RESPONSIBILITIES

Include the following; other duties may be assigned:

NPI, Process Development & Launch Support

• Lead manufacturing process development for new programs from quote/DFM review through first article and production release, coordinating and supporting across NPI phases.
• Review customer data packages (BOM, Gerbers, assembly drawings, specifications) for manufacturing requirements, design for manufacturability and ability to translate them into accurate work instructions, MES steps and ERP routings.
• Influence Design for Manufacturability (DFM) and Design for Test (DFT) by engaging early with Program Management and Customer Engineering and incorporating internal guidelines, standards and lessons learned from the production floor.
• Design, specify, and coordinate fabrication of tooling, fixtures, stencils, and test fixtures, including sourcing and cost estimates for capital or tooling spend.
• Support build events (first article, pilot, and production ramp builds), ensuring station readiness, documentation accuracy, and on-time execution.
• Serve as the senior technical reviewer and approver for manufacturing process and documentation.

Documentation, Quality & Process Control

• Own or support development of process flows, structured work instructions (SWS), control plans, and PFMEAs for assigned programs, ensuring alignment with quality requirements.
• Validate tooling and fixture capability, equipment capability, and test/measurement system capability (gauge R&R, MSA) as required.
• Identify and close manufacturing readiness gaps ahead of build milestones and production release.
• Support quality audits, corrective actions (8D), and post-release issue resolution related to new product introductions and process adherence.
• Maintain accurate, organized engineering records and documentation in accordance with company procedures and customer requirements.

Project Management & Continuous Improvement

• Apply project management tools and techniques to manage scope, cost, timing, and risk for assigned projects and deliverables.
• Maintain project plans and communicate status, risks, and readiness to Program Management and cross-functional stakeholders.
• Evaluate existing processes and recommend improvements to increase quality, reduce cost, and improve throughput, applying Lean, 5S, and Six Sigma principles.
• Use structured problem solving (8D, root cause analysis) to drive corrective and preventive actions from production feedback.
• Collect, track, and present department operational metrics as required.
• Communicate clearly with internal teams and, when necessary, external customers to resolve technical, documentation, or process questions.
• Promote and support Lean Manufacturing and continuous improvement initiatives.
• Maintain a safe and clean work environment.
• Regular on-site attendance is required to perform the essential functions of the role.

QUALIFICATIONS

Education and Experience

• Bachelor's degree in Engineering, Electronics, or a related technical field required.
• Minimum of 5 or more years of experience in electronics manufacturing, process engineering, NPI, or tooling-related roles.
• Demonstrated experience supporting New Product Introduction, launch support, production deviation controls, current production change implementation and cross-functional problem solving.
• Working knowledge of PFMEA, control plans, and manufacturing quality systems.
• Prior experience working with ERP/MES systems (Epicor, FactoryLogix, or similar) strongly preferred.

Technical Skills

• Experience with SMT processes, including:
• Familiarity with IPC-A-610 and related workmanship standards preferred.
• Ability to design or specify test fixtures, tooling, and error-proofing (poka-yoke) solutions.
• Proficiency with Microsoft Office (Excel, Word, Outlook).
• Experience with press-fit, swage, or conformal coating processes is a plus.
• Ability to read and interpret mechanical drawings, schematics, and datasheets.

Competencies

• Technical Comprehension: Ability to read, interpret, and apply technical documentation such as assembly drawings, component datasheets, and manufacturing work instructions.
• Problem Solving & Reasoning: Ability to identify issues, evaluate data, draw conclusions, and make sound decisions in both structured and fast-paced production environments.
• Mathematical Application: Ability to apply arithmetic and algebraic concepts to tooling design, capability studies, yield calculations, and process metrics.
• Project Management: Ability to plan, prioritize, and track multiple concurrent programs against schedule, cost, and quality targets.
• Communication: Able to communicate clearly and professionally with internal teams, including Engineering, Production, Quality, and Programming teams; regular interaction with customers and suppliers.

PHYSICAL DEMANDS

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions.

• Regularly required to stand, walk, sit, and use hands to handle tools or computer equipment.
• Frequently required to reach, bend, kneel, or crouch.
• Must be able to lift up to 25 pounds routinely and occasionally up to 50 pounds.
• Visual requirements include close vision, color vision, depth perception, and the ability to adjust focus.

WORK ENVIRONMENT

The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions.

• Work is performed primarily on the production floor and in an office setting within an electronics manufacturing environment.
• Exposure to moving mechanical equipment, soldering fumes, or chemicals may occur.
• Noise levels are typically moderate to high depending on the production area.
• Appropriate PPE is required and provided.

MILWAUKEE ELECTRONICS IS AN EQUAL OPPORTUNITY EMPLOYER

All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, protected veteran status, disability, or age. If you are an individual with a disability and need a reasonable accommodation in the application or hiring process, please contact Human Resources at 414-228-5000 or hr@milwaukeeelectronics.com.

For more information about our commitment to equal employment opportunity, please see this government poster: Know Your Rights: Workplace Discrimination is Illegal | U.S. Equal Employment Opportunity Commission (eeoc.gov). 

Because this job has access to controlled technology, we must comply with ITAR. Any job offers will be contingent on verification that the candidate is a U.S. person (i.e., U.S. citizen, U.S. nationals, lawful permanent resident, or individual granted asylum/refugee status in the U.S.) or can otherwise satisfy ITAR compliance requirements. If applicable, if an individual is not a U.S. person, our policy is to not take the extra step of seeking approval from the federal government for that person to work in this position.

Upon hire, the successful candidate must present acceptable proof of identity and current authorization to work in the U.S., as required on Form I-9. We do not provide sponsorship support for employment-based visas such as H-1B.