Process Engineer

Charter Manufacturing•Milwaukee, WI

1d•Onsite

About The Position

Provide technical leadership and process expertise within Operations to continuously improve the safety, quality, yield, variation and throughput of manufacturing processes and equipment. Spend time on the floor and use process knowledge, data, structured troubleshooting and testing to identify root causes, develop and validate improvements, and sustain results across shifts. Work cross-functionally to implement new products, materials, equipment and processes, address non-conformances and customer corrective actions, and solve a broad range of operational issues.

Requirements

Bachelor’s Degree in Engineering or related field.
Three plus years’ experience in a manufacturing environment improving processes.
Knowledge and experience with lean manufacturing methodologies and problem-solving techniques including Kaizen, 5S and 6σ.
Technical skills in manufacturing processes and methods including flow, layout, assembly, and production equipment.
Effective written and oral communication skills.
Self-starter with strong analytical skills.
Capacity to work in process improvement teams as a teacher, leader, and as a member.
Knowledge of Statistical Process Control (SPC), PFMEA, process control plans, process flow diagrams, and part routings.
Ability to handle multiple projects simultaneously.
Basic 2D/3D CAD software skills.
Proficient with the basis features of Microsoft Office products.

Nice To Haves

Five plus years' proven track record of leading safety, quality, and process improvement teams within a manufacturing environment.
Five plus years' experience in Heat Treat operations.
Certifications in Six Sigma Green Belt or above from a recognized lean source.
Demonstrated success in the application of lean/CI concepts in a manufacturing environment.
Experience with the Value stream approach a basis for Continuous Improvement.
Proven project management including Kaizen projects.
Experience with SolidWorks / Pro-E systems.
Proficiency with statistical and flow charting/process mapping software.

Responsibilities

Observe manufacturing processes on the floor, analyze performance data, identify recurring losses, and lead structured troubleshooting with Operations, Maintenance, Tool Room, and Quality. Use evidence, testing, and data to establish root causes and verify corrective actions.
Evaluate equipment, process parameters, tooling, setups, operator work methods, material handling, inspection methods, and operator-machine interactions to improve process performance and consistency. Apply practical experience with machine vision inspection systems, including lighting, optics, image acquisition, triggering/timing, inspection settings, and troubleshooting false accepts and false rejects; validate vision changes before implementation.
Work with operators and Operations to develop and improve standardized work, operating instructions, and process controls that support consistent results across shifts.
Design, execute, and analyze machine and process capability studies, controlled production trials, and Design of Experiments (DOE) where appropriate. Define test objectives, variables, measurement methods, sampling plans, and acceptance criteria; use results to establish operating limits and validate proposed changes.
Lead corrective and preventive action teams and cross-functional PFMEA development and reviews. Maintain PFMEAs as processes and risks change, use findings to prioritize preventive actions and verify effectiveness, and keep PFMEAs, process flows, control plans, and work instructions aligned with production practices.
Drive measurable, sustained improvements in safety, quality, scrap, variation, yield, and throughput using Process Control and Continuous Improvement methodologies. Provide technical leadership, coaching, and facilitation for the CI culture; identify barriers to improvement, recognize CI accomplishments, and use process data and operational metrics to prioritize opportunities and measure effectiveness.
Coordinate with Engineering on new component process and equipment planning and support implementation of new products, materials, equipment, and processes into Operations.
Oversee development and maintenance of heat treat procedures and practices.
Lead a limited number of small and midsized operational projects, typically one or two midsized projects and three to six smaller projects per year. Projects may include specifying and selecting replacement equipment, coordinating installation, and validating performance; develop scope, estimates, financial proposals, and execution plans as appropriate.
Follow Environmental, Quality and Safety Management System procedures and requirements, and meet the essential job requirements, with or without reasonable accommodation, as outlined in the job description.