Process Engineer - Machining, Maintenance, Refractory

Charter Manufacturing•Woodstock, IL

5d•Onsite

About The Position

Charter Casting is seeking a Process Engineer to drive continuous improvement across maintenance, refractory, and machining operations at our Woodstock, IL facility. In this role, you'll tackle meaningful engineering challenges, optimize manufacturing processes, and lead projects that improve safety, quality, productivity, and cost competitiveness. You'll collaborate with cross-functional teams to turn innovative ideas into practical solutions while helping shape the future of our manufacturing operations.

Requirements

Bachelor's degree in Engineering or a related field.
3+ years of experience improving processes in a manufacturing environment.
Experience with Lean Manufacturing and problem-solving methodologies, including Kaizen, 5S, and Six Sigma.
Knowledge of manufacturing processes, production equipment, workflow, plant layout, and assembly methods.
Working knowledge of Statistical Process Control (SPC), PFMEA, process control plans, process flow diagrams, and part routings.
Strong analytical, troubleshooting, communication, and cross-functional collaboration skills, with the ability to lead or participate in multiple improvement projects.
Basic proficiency with 2D/3D CAD software.

Nice To Haves

5+ years of experience leading safety, quality, and process improvement initiatives in manufacturing.
Experience with CNC programming and machining processes.
Six Sigma Green Belt certification or higher from a recognized organization.
Demonstrated success applying Lean Manufacturing, continuous improvement, and value stream methodologies.
Proven project management experience, including leading Kaizen events or improvement projects.
Experience with SolidWorks or Pro/ENGINEER (Pro/E).
Proficiency with statistical analysis, flowcharting, and process mapping software.

Responsibilities

Drive process improvements across maintenance, refractory, and machining operations to enhance safety, product quality, manufacturing yield, throughput, and operational efficiency.
Lead continuous improvement initiatives using Lean Manufacturing, Six Sigma, and structured problem-solving techniques to reduce process variation, eliminate waste, and improve performance.
Troubleshoot manufacturing challenges by partnering directly with production teams, analyzing process data, identifying root causes, and implementing sustainable corrective and preventive actions.
Manage engineering and capital projects from investigation and cost estimation through financial justification, equipment installation, implementation, and startup, collaborating with internal teams and external contractors.
Support new equipment and process development by partnering with Engineering and Operations to introduce new components, materials, technologies, and manufacturing methods.
Develop process standards and performance metrics, including standard operating procedures, work instructions, process control plans, and operational KPIs to drive consistency and measurable results.
Champion a culture of continuous improvement by coaching and collaborating with cross-functional teams, removing barriers to progress, and recognizing achievements that strengthen operational performance.