Sr Process Control Engineer Jobs in Phoenix, AZ (NOW HIRING)

Job Summary: 

The Process Engineer II is responsible for independently driving process performance, yield improvement, quality enhancement, and operational excellence within the Electrode Manufacturing area. This role serves as a technical subject matter expert for assigned manufacturing processes and equipment, leading complex troubleshooting efforts, process optimization projects, new technology implementation, and production ramp-up activities. The Process Engineer II partners closely with Production, Quality, Equipment Engineering, Maintenance, and R&D teams to improve safety, quality, delivery, and cost performance.

Responsibilities:

• Lead investigations of complex process and quality issues, identify root causes, and implement effective corrective and preventive actions (CAPA) to prevent recurrence.
• Independently analyze manufacturing data and process performance metrics to identify trends, variation sources, and improvement opportunities.
• Design, execute, and lead Design of Experiments (DOE) activities to optimize process capability, product quality, throughput, and cost.
• Own and continuously improve key manufacturing performance indicators including OEE, yield, scrap, process downtime, cycle time, and productivity.
• Lead qualification activities for new materials, equipment, tooling, and process technologies, including validation of process changes and performance verification.
• Develop technical reports and present findings, recommendations, and project updates to plant leadership and cross-functional stakeholders.
• Drive continuous improvement initiatives utilizing Lean Manufacturing, Six Sigma, Statistical Process Control (SPC), and other problem-solving methodologies.
• Lead non-conformance investigations and implement robust containment, corrective action, and long-term preventive measures.
• Develop, maintain, and improve PFMEAs, Process Flow Diagrams (PFDs), Control Plans, process specifications, and manufacturing standards.
• Evaluate and approve 4M (Man, Machine, Material, Method) changes and support New Product Introduction (NPI), process transfers, and manufacturing ramp-up activities.
• Serve as technical lead for assigned production lines by providing advanced troubleshooting support for process and equipment-related issues.
• Collaborate with Equipment Engineering and Maintenance teams to improve equipment reliability, process stability, and manufacturing capability.
• Analyze process capability and establish statistical control strategies to reduce variation and improve product consistency.
• Develop and revise SOPs, work instructions, and engineering standards to support operational excellence.
• Train and mentor Process Engineer I team members, technicians, and production personnel on process technologies, troubleshooting methodologies, and best practices.
• Support implementation of automation, digital manufacturing, and smart factory initiatives to improve operational efficiency.
• Participate in customer audits, internal audits, and quality system activities as required.
• Perform other duties as assigned.

Qualifications:

• Bachelor's degree in Chemical Engineering, Materials Engineering, Mechanical Engineering, Industrial Engineering, Electrical Engineering, or related engineering discipline required.
• Minimum 3 years of manufacturing engineering experience, preferably in lithium-ion battery manufacturing, semiconductor, automotive, chemical processing, or other high-volume manufacturing environments.
• Experience supporting electrode manufacturing processes including mixing, coating, drying, calendering, slitting, or related technologies preferred.
• Demonstrated experience leading process improvement projects and cross-functional technical initiatives.

Skills:

• Strong knowledge of DOE, Statistical Process Control (SPC), Process Capability Analysis, Six Sigma, and root cause analysis methodologies.
• Experience utilizing quality tools including PFMEA, Control Plans, 8D, Fishbone Analysis, Pareto Analysis, and Failure Analysis techniques.
• Ability to analyze large manufacturing datasets and translate findings into actionable process improvements.
• Proficiency with statistical analysis software such as Minitab, JMP, or equivalent analytical tools.
• Strong understanding of manufacturing process control and process validation methodologies.
• Ability to independently manage multiple projects and priorities in a fast-paced manufacturing environment.
• Strong technical writing, presentation, and communication skills.
• Effective collaboration and leadership skills with cross-functional teams.
• Ability to mentor junior engineers and provide technical guidance to manufacturing personnel.
• Strong problem-solving skills with a data-driven and continuous improvement mindset.