Process Engineer

Onyx Specialty Processing•Decatur, TX

19d•Onsite

About The Position

Onyx Specialty Processing is a surface finishing company in Decatur, Texas, serving the aerospace and defense industries. Its Nadcap-accredited shop performs anodizing, chem film, passivation, prime and paint, and fluorescent penetrant inspection to MIL-SPEC, AMS, and customer specifications. The company is growing, adding customer approvals, and developing the associated processes and tooling. The Process Engineer sets up and supports the processes technicians run. The role translates customer drawings, parts lists, purchase orders, and specifications into work instructions, routers, process limits, and fixtures. It is a hands-on, on-site role that spends time on the production floor running first parts, supporting technicians, troubleshooting issues, and verifying that processes are performed as documented. The position reports to the General Manager, works closely with the Quality Manager, Technician Supervisor, and production technicians, and has no direct reports. The engineer designs fixtures, racks, masking tools, and molds in SolidWorks and may build them in-house using FDM 3D printers and shop tools or send them to vendors. The role also supports quality documentation, audits, process qualification, PFMEA, testing, and compliance with OSHA, EPA, and company rules for chemical handling and waste.

Requirements

Must be a U.S. citizen for aerospace compliance.
Bachelor's degree in Chemical, Mechanical, Materials, or Manufacturing Engineering, or a related engineering field.
At least 5 years of process engineering experience in aerospace chemical processing or metal finishing, such as anodize, chem film, passivation, plating, or prime/paint.
Experience writing work instructions, routers, and process documentation in an aerospace or defense shop.
Ability to read engineering drawings, GD&T, parts lists, and prime or industry finishing specifications.
Proficiency in SolidWorks.
Working knowledge of Nadcap Chemical Processing and AS9100.
Clear written communication, including the ability to write instructions for technicians and documentation reviewed by Quality.
Must pass a pre-employment background check and drug screening.
Ability to translate specification language into shop-floor instructions without losing requirements.
Organized and self-directed, able to manage multiple new-part setups and meet delivery dates.
Clear communication with technicians, Quality, leadership, and customers.

Nice To Haves

Experience obtaining or maintaining approvals with major aerospace primes.
Experience with FDM 3D printing for fixtures, masking tools, and molds.
Familiarity with fluorescent penetrant inspection and aerospace prime/paint systems.
Experience with ERP/MES systems for routers, work orders, and process records.
Lean, Six Sigma, or formal root cause/corrective action training.

Responsibilities

Interpret customer drawings, parts lists, purchase orders, and specification call-outs to determine finishing, masking, contact points, critical surfaces, and inspection requirements.
Translate prime and industry specifications for anodize, chem film, passivation, prime/paint, and penetrant inspection into Onyx work instructions and process limits.
Write step-by-step routers and work instructions covering process sequence, parameters, racking and masking, hold points, and in-process checks; submit them to Quality and leadership for review.
Design fixtures, racks, masking tools, and molds in SolidWorks; build them in-house with FDM 3D printers and shop tools or arrange vendor production.
Compare current processes with new customer specifications and revisions, identify gaps, and update documentation.
Lead first-article and new-part setup on the production floor, run initial parts with technicians, make adjustments, and release parts to production.
Train technicians on new and revised instructions, observe processes, and verify that work is performed as documented.
Set process parameters, control plans, and bath chemistry limits with Quality.
Calculate surface area, current density, cycle time, and coating thickness targets for anodize and chem film work.
Troubleshoot process issues involving adhesion, thickness, burn, pitting, coverage, and appearance; conduct root cause and corrective action with production and Quality.
Identify and address sources of setup time, rework, scrap, and inconsistent results.
Work with the Quality Manager to provide process documentation and support for Nadcap, AS9100, customer, and prime approval audits.
Support process qualification, PFMEA, and periodic testing as directed by the Quality Manager.
Ensure designed processes comply with OSHA, EPA, and company rules for chemical handling and waste.