Sr Process Engineer

Rocket City HR•New Baltimore, MI

About The Position

Senior Process Engineer POSITION SUMMARY The Senior Process Engineer is responsible for developing, implementing, and validating finishing, assembly, and decoration processes that support new product launches and serial production. This role ensures all processes meet project objectives for quality, cost, delivery, and performance (QCDP), while maintaining compliance with safety and ergonomic standards. The Senior Process Engineer serves as the primary technical contact for finishing processes throughout the project lifecycle and interfacing with internal teams, suppliers, and customers to deliver robust, efficient, and cost-effective solutions. KEY RESPONSIBILITIES Product & Process Design Partner with product design teams to ensure manufacturability and compatibility with finishing processes. Evaluate feasibility, risks, and costs of finishing processes; recommend adjustments to improve quality, performance, and cost. Validate product designs for compatibility with finishing, assembly, and decoration methods. Process Definition & Development Define finishing processes in line with technical and economic project objectives. Lead workstation and time studies (MTS/MTM) and process FMEAs. Develop and present process solutions for approval, optimizing QCDP outcomes. Support mold and tooling design teams to integrate finishing and assembly requirements. Implementation of New Processes Create functional specifications for finishing and assembly equipment. Participate in supplier selection and technical validation. Monitor supplier progress, conduct technical reviews, and manage corrective actions as needed. Plan and execute Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT) to ensure equipment readiness. Provide training and technical support to production teams during process ramp-up. Project Leadership & Reporting Act as the primary technical liaison for customers and suppliers regarding finishing processes. Report progress, issues, and solutions to project leadership and Engineering management. Ensure project milestones are achieved on time and within budget. Capture lessons learned and lead continuous improvement initiatives. Continuous Improvement & Support Assess and recommend new finishing technologies and process enhancements. Support productivity, cost reduction, and quality improvement projects. Provide expert technical input to cross-functional teams and ongoing production operations.

Requirements

Master's degree in Engineering or related technical field.
10+ years of experience in process engineering with emphasis on finishing, assembly, and decoration of plastic products.
Demonstrated expertise in special machine design, implementation, and troubleshooting.
Knowledge of finishing technologies: injection peripherals, IMF/IMD, pad and screen printing, laser engraving, welding, and packaging processes.
Understanding of special machine specifications, design, safety, and automation.
Skilled in Process FMEA, time studies (MTS/MTM), Kaizen/Hoshin, and structured problem-solving methods.
Proficiency in Microsoft Office; CAD or related software preferred.
Strong organizational and project management abilities.
Excellent verbal and written communication skills.
Ability to train, mentor, and influence cross-functional teams.
Independent, detail-oriented, and results-driven.
Domestic and international travel required.
Must maintain valid travel documents and reliable transportation.
Ability to work in a fast-paced environment with multiple projects and shifting priorities.

Nice To Haves

Experience in automotive product development preferred.
Fluency in French and/or Spanish a plus.

Responsibilities

Partner with product design teams to ensure manufacturability and compatibility with finishing processes.
Evaluate feasibility, risks, and costs of finishing processes; recommend adjustments to improve quality, performance, and cost.
Validate product designs for compatibility with finishing, assembly, and decoration methods.
Define finishing processes in line with technical and economic project objectives.
Lead workstation and time studies (MTS/MTM) and process FMEAs.
Develop and present process solutions for approval, optimizing QCDP outcomes.
Support mold and tooling design teams to integrate finishing and assembly requirements.
Create functional specifications for finishing and assembly equipment.
Participate in supplier selection and technical validation.
Monitor supplier progress, conduct technical reviews, and manage corrective actions as needed.
Plan and execute Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT) to ensure equipment readiness.
Provide training and technical support to production teams during process ramp-up.
Act as the primary technical liaison for customers and suppliers regarding finishing processes.
Report progress, issues, and solutions to project leadership and Engineering management.
Ensure project milestones are achieved on time and within budget.
Capture lessons learned and lead continuous improvement initiatives.
Assess and recommend new finishing technologies and process enhancements.
Support productivity, cost reduction, and quality improvement projects.
Provide expert technical input to cross-functional teams and ongoing production operations.