Senior Process Engineer

This role provides technical leadership for manufacturing processes, equipment optimization, new product introductions, and large-scale continuous improvement initiatives to achieve world-class safety, quality, delivery, and cost performance in a high-volume, highly automated manufacturing facility.

Responsibilities

• Provide technical leadership and engineering support for all production operations.
• Develop, optimize, and standardize manufacturing processes to improve safety, quality, productivity, and cost.
• Design and maintain manufacturing work instructions, process documentation, and standard operating procedures.
• Establish best practices that improve process consistency and manufacturing reliability.
• Support new product introductions, equipment launches, and production transfers.
• Lead complex, cross-functional capital and operational improvement projects.
• Develop project timelines, budgets, resource plans, launch curves, and risk mitigation strategies.
• Create project dashboards and tracking systems to ensure milestones, deliverables, and financial targets are achieved.
• Coordinate activities between Engineering, Operations, Quality, Automation, Supply Chain, Maintenance, and external suppliers.
• Present project status and business results to plant leadership.
• Lead Lean Manufacturing, Six Sigma, Kaizen, and Value Stream Mapping initiatives throughout the facility.
• Identify opportunities to reduce manufacturing cost, improve throughput, eliminate waste, and increase equipment utilization.
• Utilize data analytics to identify process bottlenecks and prioritize improvement opportunities.
• Lead structured problem-solving activities utilizing DMAIC, 8D, 5 Why, Fishbone Analysis, and FMEA.
• Investigate manufacturing failures, field returns, and customer complaints.
• Validate corrective and preventive actions (CAPA) to eliminate recurring issues.
• Support production during critical downtime events and major quality issues.
• Analyze manufacturing KPIs including Overall Equipment Effectiveness (OEE), First Pass Yield (FPY), Throughput, Cycle Time, Scrap, Rework, Labor Efficiency, Cost per Unit, and Capacity Utilization.
• Utilize statistical analysis and manufacturing data to drive operational decisions.
• Develop reports and dashboards using Excel, Power BI, or similar analytical tools.
• Partner with Production, Maintenance, Automation, Quality, Materials, Supply Chain, Product Engineering, and Customers to achieve operational objectives.
• Coordinate with suppliers on component issues and alternate material qualifications.
• Support manufacturing readiness during new product launches.
• Lead engineering reviews and communicate technical recommendations to leadership.
• Mentor Process Engineers and coach manufacturing supervisors and production teams on Lean Manufacturing principles.
• Provide technical guidance during equipment startups and process improvements.
• Lead engineering knowledge-sharing and technical training sessions.

Requirements

• Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, Electrical Engineering, or related engineering discipline.
• 7+ years of manufacturing engineering experience in a high-volume manufacturing environment.
• Experience leading large cross-functional manufacturing projects.
• Strong project management experience with budgets, schedules, and resource planning.
• Demonstrated experience in Lean Manufacturing and Six Sigma methodologies.
• Experience with highly automated manufacturing systems.
• Strong analytical and statistical problem-solving skills.
• Proficient with Microsoft Excel, Word, PowerPoint, and Project.
• Experience using AutoCAD for manufacturing layouts.
• Excellent communication and leadership skills.

Preferred Skills

• Experience in consumer electronics, wireless devices, or electronics refurbishment.
• Experience in high-volume automated manufacturing facilities.
• Lean Six Sigma Green Belt required; Black Belt preferred.
• Knowledge of Statistical Process Control (SPC), Minitab, and process capability analysis.
• Experience supporting robotics, vision systems, conveyors, and automated material handling.
• Power BI or advanced manufacturing analytics experience.
• Experience supporting New Product Introduction (NPI) and product launches.

Schedule

Monday - Friday, 8AM – 5PM (onsite in Mt. Juliet, TN).

Pay

$74,600.00 - $124,700.00 per year.