Senior Process Engineer

Kinetic Engine Systems • Orange, CT

27d • $110,000 - $135,000 • Onsite

About The Position

The Manufacturing Process Engineer will develop and manage manufacturing processes for complex aerospace components from start to finish. This position will take ownership of parts from initial drawing and model review through process planning, development of operational instructions, design of fixturing, production release, shop support, troubleshooting, and continuous improvement.

Requirements

• Bachelor's degree in Manufacturing Engineering, Mechanical Engineering, or a related engineering discipline preferred; equivalent relevant experience may be considered.
• 5+ years of direct aerospace manufacturing experience required.
• Significant experience in manufacturing engineering, process engineering, or a similar role supporting precision-machined aerospace components.
• Strong understanding of CNC machining and manufacturing processes; CNC programming experience is beneficial but not required.
• Experience developing manufacturing processes for complex, close-tolerance components.
• Strong knowledge of cutting tools, tooling applications, fixtures, workholding, machining methods, and process development.
• Ability to read and interpret complex engineering drawings, specifications, and GD&T.
• Experience supporting machine setups, first-piece runs, process prove-outs, and production launches.
• Demonstrated experience troubleshooting manufacturing and dimensional issues and implementing effective corrective actions.
• Experience with root-cause analysis, continuous improvement, and process optimization.
• Knowledge of aerospace quality systems and requirements, including AS9100.
• Familiarity with CAD/CAM and ERP/manufacturing systems is preferred.
• Strong analytical, problem-solving, and decision-making skills.
• Strong communication skills with the ability to work effectively with machinists, programmers, Quality personnel, engineers, and management.
• Ability to manage multiple projects and manufacturing priorities in a fast-paced environment.

Nice To Haves

• CNC programming experience is beneficial but not required.
• Familiarity with CAD/CAM and ERP/manufacturing systems is preferred.

Responsibilities

• Own the manufacturing process for assigned aerospace components from initial review through successful production release.
• Review customer drawings, CAD models, specifications, tolerances, GD&T, and technical requirements to determine manufacturing needs.
• Develop manufacturing process plans, including operation sequences, machine requirements, tooling, workholding, inspection points, and production methods.
• Determine the most effective manufacturing approach for complex, close-tolerance aerospace components.
• Collaborate with CNC programmers to ensure programs align with the intended manufacturing process and production requirements.
• Work directly with machinists and operators during setups, first-piece runs, process prove-outs, and production launches.
• Identify and troubleshoot machining, tooling, dimensional, and manufacturing process issues.
• Analyze inspection and production results and implement process changes necessary to achieve consistent, conforming product.
• Develop and improve tooling, fixtures, workholding methods, and manufacturing techniques.
• Partner with Quality and Inspection personnel to ensure processes meet drawing, GD&T, customer, and aerospace quality requirements.
• Develop and maintain manufacturing documentation, including routers, work instructions, setup requirements, process specifications, and other technical documentation.
• Lead root-cause analysis and corrective action efforts related to manufacturing nonconformances and process failures.
• Identify and implement opportunities to improve cycle time, throughput, tool life, quality, process capability, and overall manufacturing efficiency.
• Support new product introduction (NPI) and the transition of new or revised aerospace components into production.
• Evaluate existing manufacturing processes and recommend improvements to increase repeatability, reduce scrap and rework, and improve productivity.
• Provide technical guidance and mentorship to junior engineers and manufacturing personnel.
• Collaborate across Engineering, Quality, Operations, Supply Chain, and Production to resolve technical and manufacturing challenges.
• Ensure manufacturing processes comply with applicable aerospace quality standards, customer requirements, and internal procedures.

What This Job Offers

• Job Type: Full-time
• Career Level: Senior