Process Engineer

About the role

The Process Engineer supports manufacturing operations by providing technical guidance on shop floor methods and processes for assigned equipment. Maintains and ensures the accuracy of Manufacturing Process Planning documentation and labor standards. Drives continuous improvement initiatives to enhance Safety, quality, delivery and cost reduction.

This position is located on site in Blacksburg, VA. (no remote work).

What you'll do

• Provide process input to design engineering, including tooling, fixtures, validation, and ensuring key characteristics and tolerances are defined.
• Collaborate with product and process development teams to establish robust manufacturing processes, including PFMEA, validation/verification, documentation (DHR/DMR), and final product release.
• Lead and implement continuous improvement initiatives, including Lean Six Sigma projects, Kaizen workshops, 5S, value stream mapping, and manufacturing optimization to improve safety, quality, efficiency, and cost performance.
• Develop, update, and maintain all manufacturing process documentation (e.g., process plans, routings, BOMs, SMPs, Work Instructions), ensuring compliance with engineering changes and quality system requirements.
• Apply advanced methodologies (DOE, FMEA, SPC, Cpk, Gage R&R) and structured problem-solving techniques to reduce variation, enhance process capability, and resolve production issues.
• Provide technical support and training to shop floor personnel, resolving production issues and driving improvements in manufacturing processes.
• Partner with suppliers and purchasing teams to interpret drawings, develop manufacturing documentation, resolve technical issues, and recommend equipment acquisitions to improve manufacturing capability.
• Identify and implement improvements in manufacturing methods to enhance product quality, schedule performance, and reduce manufacturing costs.
• Ensure compliance with customer requirements and quality standards by supporting audits, corrective/preventive actions, process validations, and capacity analyses.
• Travel as required to support business needs.
• Perform additional duties as needed, such as print checking, fixture design, and process validation.

Qualifications

• Bachelor’s degree in an engineering discipline (BSME, BSIE) with at least 2 years of relevant experience in a manufacturing environment providing direct process support.
• Experience using risk management tools such as PFMEA and control plans.
• Knowledge of metal stamping and rubber coating manufacturing is preferred.
• Training and experience in practices such as TPM, FMEA, SPC, DOE, VSM, 5S, and Lean Six Sigma is strongly preferred.
• Shainin Red X and Six Sigma Green Belt certification preferred.
• Proficient in PC-based software, including word processing, spreadsheets, project management, statistical analysis, and CAD/CAM tools.
• Values others’ ideas and demonstrates experience working effectively in a team environment.
• Able to work well with a diverse group of people.
• Works well under pressure and manages multiple projects simultaneously.
• Strong analytical and problem-solving skills.
• Results-oriented self-starter with initiative.
• Excellent oral and written communication skills.