Process Engineer

douglas electrical components•Randolph Township, NJ

8d•Hybrid

About The Position

The Process Engineer is responsible for developing, implementing, and continuously improving manufacturing processes to ensure they are scalable, repeatable, and capable of meeting quality, cost, and delivery objectives. This role serves as the technical owner of assigned processes, supporting New Product Introduction (NPI), process validation, and ongoing production performance. The Process Engineer executes engineering strategies defined by leadership, ensuring processes are statistically capable, compliant with the Quality Management System (QMS), and aligned with business objectives. Working cross-functionally with Quality, Production, Applications Engineering, and Supply Chain, this position plays a key role in driving process stability, yield improvement, scrap and rework reduction, throughput improvement, and data-driven decision-making in a high-mix, low-volume manufacturing environment.

Requirements

Working knowledge of process development, DFM/DFA, validation techniques, and statistical methods (DOE, Cp/Cpk, SPC) in a manufacturing environment.
Ability to collect and analyze process data, identify trends, and make fact-based decisions to improve process performance and stability.
Strong capability in structured problem-solving (RCA, 8D, DMAIC) to eliminate root causes and implement sustainable improvements.
Ability to work effectively with Quality, Production, Applications Engineering, and Supply Chain to drive alignment and execution.
Able to translate engineering direction into actionable tasks and deliver results with a high level of ownership, accountability and attention to detail.
Strong written and verbal communication skills, with the ability to clearly present technical information at all organizational levels.
Ability to document technical findings, process changes, and validation results clearly and accurately to support effective decision-making and compliance.
Working knowledge of tooling, fixturing, and equipment qualification concepts, including the ability to support implementation and validation activities.
Ability to manage process changes with strong documentation discipline, ensuring updates are controlled, communicated, and sustained in accordance with QMS requirements.
Comfortable working in a high-mix, low-volume environment requiring flexibility, prioritization, and responsiveness.

Nice To Haves

Experience supporting NPI, process validation, and transition from prototype to production preferred.
Working knowledge of AS9100 and ISO 9001 requirements and their integration into manufacturing processes.
Experience in regulated industries such as aerospace, defense, or medical devices.
Experience in high-mix, low-volume manufacturing environments is strongly preferred.
Professional certification such as Six Sigma Green Belt, Lean Manufacturing, or equivalent is highly desirable.
Proven track record in cross-functional collaboration to implement and sustain process improvements.

Responsibilities

Own and support assigned manufacturing processes, ensuring they are stable, repeatable, and capable of meeting customer, quality, and production requirements.
Execute process development and industrialization activities from prototype through full-rate production under the direction of the Facilities & Process Engineering Manager.
Develop and maintain process documentation including work instructions, process flows, PFMEAs, and control plans, ensuring alignment with QMS requirements.
Establish and validate process capability using statistical methods (Cp/Cpk, DOE, SPC), ensuring processes meet defined performance criteria.
Support successful completion of NPI deliverables including DFM/DFA, FAI, PPAP, and process validation activities.
Monitor process performance through data collection and analysis, identifying trends and driving corrective actions to improve yield, reduce variation, and minimize cost of poor quality.
Lead and participate in structured problem-solving activities (8D, root cause analysis) related to process issues, nonconformances, and customer concerns.
Support implementation and maintenance of SPC and real-time process monitoring systems to enable data-driven decision-making.
Collaborate with Quality, Production, Applications Engineering, and Supply Chain to ensure process compliance, effective implementation, and alignment with operational needs.
Support tooling, fixture, and equipment development activities, including design input, qualification, and validation.
Drive continuous improvement initiatives focused on increasing throughput, reducing waste, improving quality, and enhancing process robustness.
Assist in training operators and technicians on processes, ensuring consistent execution and adherence to defined standards.