Lead Process Engineer

CompoSecure•Somerset, NJ

1d•Onsite

About The Position

Perform the following job duties in a premium metal credit card manufacturing environment, with a focus on high-quality production standards and precision-driven processes. Understand the end-to-end metal credit card manufacturing process, from raw material selection through final product delivery and lifecycle management. Use diverse manufacturing techniques including precision material assembly, thermal lamination, CNC machining, and advanced vision inspection systems to ensure high-quality, high-volume card production. Drive yield improvement projects, utilize advanced data-driven methods (SPC, FMEA, 5 Whys, Fishbone) to identify and eliminate root causes of scrap, rework, and process variation. Oversee and coordinate new product introduction (NPI) activities, including process validation, work instruction development, and ramp-up readiness. Collaborate with Quality, Maintenance, and Operations leadership to develop and execute strategic initiatives focused on cost reduction, efficiency, and throughput. Develop, review, and approve standard operating procedures, process documentation, and training materials for manufacturing staff. Implement Lean manufacturing and Six Sigma techniques to reduce waste and improve process control. Monitor and analyze key performance indicators (KPIs) for yield, cycle time, downtime, and quality, providing regular reporting and strategic action planning. Represent the process engineering function in audits, customer visits, and internal reviews as a technical subject matter expert. Ensure compliance with safety, quality, and regulatory standards applicable to manufacturing operations. Prioritize and manage multiple projects to ensure critical processes impacting business results are addressed. Ensure thorough documentation of existing and new processes, including progressive results, equipment parameters, and work instructions. Perform the foregoing using Lean, Six Sigma, SPC, and other process control methodologies, data analysis tools (Excel, Minitab, JMP, etc.) and manufacturing systems (MES, ERP).

Requirements

Bachelor's degree in Mechanical Engineering
5 years of experience in job offered or 5 years of experience in the Related Occupation
Perform the following job duties in a premium metal credit card manufacturing environment, with a focus on high-quality production standards and precision-driven processes.
Demonstrating expertise in ISO/IEC 7811-1, INCITS 440, and CQM quality standards, with a strong understanding of their application in metal card manufacturing and quality assurance processes.
Participating with Quality Assurance Manager in root cause and corrective action investigations.
Simulating possible usage conditions that may have caused the failure and recommend corrective actions.
In support of New Product, Process and Material Introduction provide thermal simulations and apply FEA of the product, process or material being considered.
Document existing processes and new process development, inclusive of progressive results, specific equipment parameters and work instructions where appropriate.
Working with team members, based on collected yield data, work to reduce process scrap by simulating process steps that exhibit the failure.
Periodically audit operations staff to ensure the approved procedures are consistently followed.
Documenting deviations and ensuring they are formally communicated for corrective action, through use of our Non-Conformity process.
Demonstrating ability to prioritize tasks to ensure most critical processes impacting business results are being addressed.
In coordination with Manufacturing Managers, ensure work instructions are developed for all processes within the determined process window and that all operators are properly trained in accordance with the approved procedures.

Responsibilities

Demonstrate expertise in ISO/IEC 7811-1, INCITS 440, and CQM quality standards, with a strong understanding of their application in metal card manufacturing and quality assurance processes.
Oversee coating processes for stainless steel substrates, tailored for UV inkjet printing applications, including qualification and scale-up for production.
Perform statistical analysis of manufacturing yields to identify performance gaps, drive continuous improvement initiatives, and strategically plan and deploy process enhancements to optimize yield and reduce production costs.
Prepare and present technical proposals and improvement plans to senior leadership, championing initiatives that enhance product quality, reduce waste, and support strategic growth.
Travel to vendor sites to perform detailed engineering audits and collaborate on developing supplier quality requirements that align with rigorous manufacturing and product excellence standards.
Drive yield improvement projects, utilize advanced data-driven methods (SPC, FMEA, 5 Whys, Fishbone) to identify and eliminate root causes of scrap, rework, and process variation.
Oversee and coordinate new product introduction (NPI) activities, including process validation, work instruction development, and ramp-up readiness.
Collaborate with Quality, Maintenance, and Operations leadership to develop and execute strategic initiatives focused on cost reduction, efficiency, and throughput.
Develop, review, and approve standard operating procedures, process documentation, and training materials for manufacturing staff.
Implement Lean manufacturing and Six Sigma techniques to reduce waste and improve process control.
Monitor and analyze key performance indicators (KPIs) for yield, cycle time, downtime, and quality, providing regular reporting and strategic action planning.
Represent the process engineering function in audits, customer visits, and internal reviews as a technical subject matter expert.
Ensure compliance with safety, quality, and regulatory standards applicable to manufacturing operations.
Prioritize and manage multiple projects to ensure critical processes impacting business results are addressed.
Ensure thorough documentation of existing and new processes, including progressive results, equipment parameters, and work instructions.
Perform the foregoing using Lean, Six Sigma, SPC, and other process control methodologies, data analysis tools (Excel, Minitab, JMP, etc.) and manufacturing systems (MES, ERP).