Senior Process Engineer Jobs in Ames, IA (NOW HIRING)

Position Summary

The Process Engineer is responsible for designing, developing, optimizing, and sustaining manufacturing processes that ensure safe, efficient, cost-effective, and high-quality production. This role focuses on continuous improvement, process standardization, capacity expansion, waste reduction, and implementation of best practices to improve operational performance. The Process Engineer works closely with Production, Quality, Engineering, Maintenance, Supply Chain, and Operations teams to deliver reliable manufacturing processes that meet customer and business requirements.

Key Responsibilities

Manufacturing Process Design

• Design and develop manufacturing processes for new and existing products, including fixtures, workholdings, components, etc. for production.
• Design and develop prototype components and assemblies based on customer requirements.
• Create process flows, work instructions, standard operating procedures (SOPs), and process documentation.
• Define equipment, tooling, fixtures, and automation requirements.
• Generate product quotes based on inputs such as customer requirements, manufacturing processes, material and manpower usage, and capital investment needs.
• Lead process development activities from concept through production launch.
• Conduct process capability studies and validate new manufacturing processes.
• Support plant layouts and workflow optimization to improve productivity and material flow.

Process Improvement & Continuous Improvement

• Identify opportunities to improve safety, quality, delivery, and cost performance.
• Lead Lean Manufacturing and Six Sigma initiatives.
• Analyze production data to identify bottlenecks, waste, and non-value-added activities.
• Implement corrective and preventive actions to improve process stability.
• Drive cycle time reduction, throughput improvements, and overall equipment effectiveness (OEE) enhancements.
• Facilitate Kaizen events and continuous improvement projects.

Quality & Process Control

• Develop and maintain process control plans and quality standards.
• Investigate process-related quality issues and implement root cause corrective actions.
• Utilize statistical tools such as SPC, process capability analysis, and DOE.
• Support audit activities and compliance requirements.
• Ensure manufacturing processes consistently meet customer and regulatory requirements.

Project Management

• Lead capital and process improvement projects.
• Develop project scopes, schedules, budgets, and implementation plans.
• Coordinate cross-functional teams during project execution.
• Manage equipment installations, commissioning, and process qualification activities.
• Monitor project performance and report progress to stakeholders.

Operational Support

• Provide technical support to production teams.
• Troubleshoot manufacturing process issues and implement sustainable solutions.
• Support maintenance and reliability initiatives.
• Train operators and technicians on new and existing processes and equipment.
• Monitor key process performance indicators and drive action plans when targets are not achieved.

Safety & Compliance

• Promote a strong safety culture and ensure compliance with company safety policies.
• Participate in process hazard analyses and risk assessments.
• Identify and mitigate potential environmental, health, and safety risks.
• Support compliance with applicable regulatory and industry standards.

Required Qualifications

• Bachelor's degree in Engineering/Manufacturing and 1+ year of relevant experience preferred (Industrial, Mechanical, Manufacturing, Chemical, or related field). or
• Associate Degree in relevant fields and 3+ years of manufacturing/engineering experience acceptable.
• Experience with process design, process optimization, and manufacturing operations.
• CNC machining center, and/or lathe or other machining experience, requiring the manufacturing (set-up, operation, programming, and part checking) of close tolerance, high quality parts.
• Strong analytical and problem-solving skills.
• Proficiency with Microsoft Office and engineering CAD modeling tools, such as Onshape, Autodesk, Solidworks.

·        Requires the ability to physically move, lift, carry, and manipulate light to medium loads as needed (15 – 25 lbs.)

Preferred Qualifications

• Lean Manufacturing Experiences.
• Six Sigma certification or project experiences.
• Experience with automation, robotics, or Industry 4.0 technologies.
• Experience with ERP and Manufacturing Execution Systems (MES).
• Knowledge of statistical analysis and data visualization tools.
• Project Management certification (PMP) preferred.

Knowledge Requirements

Manufacturing & Engineering

• Manufacturing processes and production systems.
• Process design and industrial engineering principles.
• Production planning and capacity analysis.
• Automation and controls fundamentals.
• Equipment reliability and maintenance concepts.
• Product and process validation methodologies.

Continuous Improvement

• Lean Manufacturing principles.
• Six Sigma methodologies.
• Value Stream Mapping (VSM).
• Kaizen and continuous improvement techniques.
• Root Cause Analysis (5 Why, Fishbone, Fault Tree Analysis).
• Overall Equipment Effectiveness (OEE).

Quality Systems

• Statistical Process Control (SPC).
• Process Capability Analysis (Cp, Cpk).
• Design of Experiments (DOE).
• Failure Mode and Effects Analysis (FMEA).
• Control Plans and Quality Management Systems.
• Corrective and Preventive Action (CAPA).

Project & Business Knowledge

• Project management principles.
• Cost reduction and productivity improvement methodologies.
• Budget management and capital project justification.
• Risk assessment and mitigation techniques.
• Supply chain and material flow concepts.

Key Skills

Technical Skills

• Ability to read and correctly interpret technical drawings and sepcifications.
• Manufacturing process design and optimization.
• Data analysis and statistical evaluation.
• Process mapping and workflow analysis.
• Equipment specification and validation.
• CAD and engineering software proficiency.
• Automation and controls understanding.

Analytical Skills

• Root cause analysis.
• Problem-solving and decision-making.
• Process troubleshooting.
• Quantitative analysis and reporting.
• Risk assessment.

Leadership & Communication Skills

• Project leadership.
• Cross-functional collaboration.
• Training and coaching.
• Technical writing and documentation.
• Presentation and stakeholder communication.
• Change management and influence.

Engaged in the manufacturing of precision components for various industries. CNC lathing and machining, assembly and testing.