Manufacturing/Process Engineer

About the role

Gemini is seeking a Manufacturing Engineer to join our team in Decorah, IA. This position supports the company's goals and vision by developing, maintaining, and improving production processes.

Responsibilities

• Maintain process performance and respond to process issues.
• Develop, document, and maintain work instructions, process flows, routings, and standard work.
• Analyze production data to identify process improvement opportunities.
• Implement process changes to improve safety, quality, efficiency, and throughput.
• Support new product or process introductions by assisting with process setup, trials, and documentation.
• Drive and actively participate in continuous improvement initiatives using Lean, Six Sigma, and related methodologies.
• Lead root cause analysis efforts and implement corrective and preventive actions to address process issues.
• Proactively identify and eliminate waste, reduce scrap, minimize labor inefficiencies, and lower material costs.
• Champion kaizen events and consistently monitor improvement metrics and results.
• Sustain process improvements by updating documentation and conducting operator training sessions.
• Lead capital project initiatives by overseeing all phases, including equipment selection, justification, installation, and startup, to enhance operational capabilities and support business objectives.
• Develop and support capital requests by preparing ROI analyses and technical specifications that align with organizational goals and cost reduction strategies.
• Cross-functionally collaborate with vendors, Maintenance, and Operations teams to ensure seamless equipment installation and successful commissioning.
• Support process validation, capability studies, and acceptance testing for new or modified equipment to ensure compliance with quality, safety, and performance standards.
• Maintain and update documentation, standard work, and process instructions to reflect changes following capital project implementation, ensuring sustained improvements and knowledge transfer.
• Proactively support manufacturing processes by ensuring alignment with internal quality systems and customer requirements, driving continuous improvement and operational excellence.
• Assist with non-conformance investigations and implementing corrective actions to maintain high standards of product quality and compliance.
• Incorporate safety, ergonomics, and risk mitigation strategies into process design and improvement efforts, fostering a safe and efficient work environment.
• Contribute to internal audits and documentation reviews, ensuring sustained compliance and process reliability.
• Champion a culture of quality, safety, and continuous improvement throughout the shop floor to consistently achieve business objectives.

Qualifications

• Bachelor’s degree in Engineering (Manufacturing, Industrial, Mechanical, or related field) required.
• 4–7 years of hands-on manufacturing or process engineering experience in a production environment.
• Demonstrated ability to independently analyze, improve, and sustain manufacturing processes.
• Strong working knowledge of process capability, cycle time analysis, scrap reduction, and efficiency metrics.
• Proven experience developing and maintaining detailed work instructions, standard work, and process documentation.
• Experience supporting capital equipment installation, commissioning, and process validation activities.
• Advanced problem-solving skills with practical application of root cause analysis methodologies.
• Skilled at interpreting engineering drawings, specifications, and manufacturing data.
• Excellent written and verbal communication skills for effective cross-functional collaboration.
• Ability to work hands-on in a manufacturing environment, including providing off-shift support as required.