Senior Process Engineer - Manufacturing

Summary:
• To engineer complete manufacturing process for mechanical parts & light assemblies. (Core Process, CNC Machining, CAM ie: Master CAM, ESPRIT, CAD ie: Solid Works, Auto Desk Inventor)
• To perform mechanical design tasks in CAD as needed for work holding, special tooling and assembly aids.
• To measure & improve processes for efficiency & effectiveness.
• To work out project management tasks. (overviews, scheduling, costs, internal alignment with related teams and external with customer / sub-contractors)
• Drafts complete process flow of new projects / components including estimated process times.
• Identify & Document potential process risk and countermeasures

Overview:

• The Level 3 Process Engineer is a Subject Matter Expert in the area of precision and ultra-precision machining. Expertise must include CNC Milling, Turning and Grinding.
• They must have extensive experience reviewing and specifying requirements for other processes such as plating, heat treatment and cleaning.
• They must be able to review customer technical product documentation and translate it into executable manufacturing plans.
• They must have CAD and MS Office skills and experience with routings and BOMs in an ERP system.
• They must be able to make data driven process improvement decisions.
• They must be able to manage projects when required.

Essential Duties and Responsibilities include the following. Other duties may be assigned:

• Design and develop manufacturing processes to optimize productivity and workflow.
• Provide process documentation and detailed operating instructions.
• Oversee implementation of new processes and procedures.
• Examine existing processes and suggest improvements in methods and tooling.
• Investigate and troubleshoot any problems that arise with processes, procedures, and operations.
• Monitor job performance KPIs (Quality, Delivery and Cost) and proactively investigate under-performing processes.
• Prepare detail cost estimates for quotes.
• Perform risk assessments and participate in pFMEAs and 8Ds.
• Lead and support improvement projects - LEAN deployment, 6S, and Continuous Improvement
• Support other team members to ensure achievement of overall business goals.
• Ensures all manufacturing process documentation is published and ready for the shop (programs, tooling lists, setup lists, fixturing).
• Supports emerging support requests from Operations.
• When requested, manage specific projects including develop and tracking an MS project schedule in cooperation with a program manager. This could include Capital Equipment installations or new product development.

Knowledge:

To perform the job successfully, an individual should demonstrate the following competencies:

• Functional knowledge and understanding of core manufacturing processes such as toolmaking, assembly, and inspection.
• Experience with exotic metals including Inconel, Titanium and Metal Matrix Composites
• Working knowledge of process engineering software packages (either MASTERCAM or Solidworks) is required. Experience with other CAD may be considered with a commitment to be trained in Solidworks.
• Knowledge of GD&T and industry technical standards.
• Knowledge of Lean Six Sigma continuous improvement concepts.

Skills Required:

• Ability to read and interpret documents such as drawings, specifications, and procedures.
• Ability to facilitate problem solving using tools such as 8-D, 5-Whys, etc.
• Excellent computer skills with strong knowledge of Microsoft Office products Excel, Word, and PowerPoint. Ability to use Microsoft Project preferred.
• Good Communication skills. Both Verbal and Written.

Education and/or Experience:

• Bachelor of Science in Engineering (Industrial Engineering, Manufacturing Engineering, Mechanical Engineering) Preferred.
• Lean Six Sigma Green Belt certification preferred.
• 10 years of experience in Production/Process Engineering with heavy CNC machining emphasis.

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 accommodations may be made to enable individuals with disabilities to perform the essential functions.

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