Sr. Manufacturing Process Engineer

Barnes•Warren, MI

About The Position

The Sr. Manufacturing Process Engineer will independently plan, develop, implement, validate, and continuously improve manufacturing processes for complex aerospace components. This role provides decisive, responsive shop-floor engineering support, develops and optimizes CNC machining strategies, and interprets customer requirements. The engineer will troubleshoot metrology results, create and maintain manufacturing documentation, lead technical investigations, and coordinate technical requirements with various departments and external parties. This position also involves managing multiple projects, supporting quotations, developing process qualifications, participating in continuous improvement, and mentoring less-experienced personnel.

Requirements

Bachelor's degree in Manufacturing, Mechanical, Industrial, Aerospace Engineering, or a closely related discipline; equivalent combination of education and directly relevant experience may be considered.
10 or more years of progressive manufacturing/process engineering experience in a complex machining environment; aerospace or similarly regulated, high-mix, low-volume manufacturing experience strongly preferred.
Advanced ability to read, analyze, and apply engineering drawings, models, customer specifications, and ASME Y14.5 GD&T requirements.
Experience with CAD/CAM systems; Siemens NX experience is preferred. Working knowledge of 3D modeling and preparation of clear, usable shop documentation is required.
Experience with ERP systems and controlled manufacturing documentation, including routings, BOMs, work instructions, and item master records.
Working knowledge of AS9100 quality-system expectations and aerospace special-process controls; Nadcap familiarity is preferred.
Demonstrated ability to lead multiple technical projects, organize competing priorities, communicate concise status and risk, and deliver under production pressure.
Clear written and verbal communication skills, with the judgment to work effectively from the shop floor through executive management and with customers or suppliers.

Nice To Haves

Approximately 15 years of relevant experience is preferred.
Siemens NX experience is preferred.
Nadcap familiarity is preferred.

Responsibilities

Independently plan, develop, implement, validate, and continuously improve manufacturing processes for complex aerospace components, including machining, welding, heat treatment, EDM, plasma spray, NDT, and other special processes.
Provide decisive, responsive shop-floor engineering support for production interruptions, setup issues, machining instability, tooling failures, dimensional nonconformance, and process capability concerns.
Develop and optimize CNC machining strategies, cutting parameters, tooling, workholding, and fixtures for multi-axis milling, turning, grinding, and related operations; support prove-outs and production transitions.
Interpret customer drawings, models, specifications, and contractual requirements; apply ASME Y14.5 GD&T principles to establish functional datum strategies, inspection approaches, and manufacturable process plans.
Troubleshoot CMM and other metrology results, distinguish measurement-system issues from product variation, and work with Quality and inspection personnel to establish reliable measurement methods and disposition paths.
Create and maintain manufacturing plans, operation sheets, work instructions, tooling requirements, routings, BOMs, item records, and other controlled engineering documentation in ERP and related systems.
Lead technical investigation, material review support, root-cause analysis, corrective action, and recurrence prevention for internal and customer-reported nonconformances.
Coordinate technical requirements with Quality, Operations, Program Management, Supply Chain, customers, and outside processors; ensure processes and tooling meet applicable customer, organizational, regulatory, AS9100, and Nadcap requirements.
Manage multiple projects and production priorities, establish realistic milestones, communicate risk and status clearly to management, and drive work to closure without close day-to-day supervision.
Support quotation and make/buy decisions through manufacturability reviews, process concepts, tooling estimates, risk identification, and technical input to cost and schedule assumptions.
Develop process qualifications, first-article support, validation plans, and production-readiness activities as required for new or revised products and processes.
Participate in continuous-improvement initiatives that improve safety, quality, delivery, cost, setup time, throughput, and process repeatability.
Mentor less-experienced engineers, programmers, and technical personnel through sound problem-solving practices, process discipline, and effective communication.