Sr Process Engineering Manager

About Us

Founded in 1944, HSM is a third-generation, privately held company with a rich history of innovation and a commitment to our people. With 25 locations across the U.S. and corporate headquarters in Hickory, NC and Huntersville, NC, we specialize in manufacturing components for furniture, bedding, transportation, packaging, automotive, and healthcare industries. Our expertise also includes designing and building automated production machinery. HSM products—from sofa springs to swimming pool noodles and bus seats—touch everyday life in countless ways.

At HSM, our success is built on our people. We foster a culture of teamwork, innovation, and shared success. If you’re looking for a meaningful place to grow and make an impact, we want to hear from you!

Responsibilities

• Provide technical leadership and direction to Process and Manufacturing Engineering teams across multiple facilities.
• Establish consistent engineering methods, documentation, performance metrics, and best practices.
• Strengthen process capability and manufacturing performance across the division.
• Mentor engineering professionals and build a strong, collaborative technical organization.
• Develop, validate, optimize, and standardize processes across metal fabrication, welding, foam, cut-and-sew, and final assembly operations.
• Improve safety, quality, throughput, labor utilization, equipment performance, and overall manufacturing efficiency.
• Lead structured root-cause investigations using engineering analysis and data-driven decision-making.
• Advance line balancing, capacity planning, workstation design, material flow, tooling, fixtures, and ergonomic improvements.
• Drive measurable reductions in scrap, cycle time, waste, and manufacturing cost.
• Guide manufacturing-readiness activities from early concept through start of production.
• Lead and support APQP deliverables, including process flow diagrams, PFMEAs, control plans, manufacturing validation, Run-at-Rate, and PPAP submissions.
• Partner with Product Development to improve design for manufacturability, design for assembly, and production scalability.
• Coordinate prototype builds, manufacturing trials, engineering validation, production transfers, and structured launch reviews.
• Partner with Controls Engineering to implement equipment upgrades, automation solutions, manufacturing technologies, and capital projects.
• Support robotics, PLC-controlled equipment, vision systems, automated inspection, data collection, production analytics, and Industry 4.0 initiatives.
• Participate in equipment evaluation, selection, commissioning, startup, and performance monitoring.
• Lead Lean Manufacturing, Kaizen, Six Sigma, VAVE, and structured problem-solving initiatives.
• Improve OEE, process capability, and manufacturing performance across multiple facilities.
• Apply statistical analysis, SPC, Design of Experiments, and other engineering methodologies to solve complex operational challenges.
• Prioritize projects based on customer needs, operational performance, financial impact, and long-term business strategy.

Requirements

• Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, or a related technical discipline; master’s degree preferred.
• At least eight years of progressive manufacturing or process engineering experience.
• At least five years of engineering leadership experience.
• Demonstrated success leading teams or engineering initiatives across multiple manufacturing facilities.
• Experience in automotive, commercial transportation, specialty vehicle, recreational vehicle, or Tier 1/Tier 2 manufacturing strongly preferred.
• Broad manufacturing-process expertise, including metal fabrication, MIG and laser welding, foam, cut-and-sew, and mechanical assembly.
• Experience with tooling, fixtures, process validation, line balancing, capacity planning, material flow, and ergonomics.
• Working knowledge of PLC-controlled equipment, robotics, automation systems, and advanced manufacturing technologies.
• Strong knowledge of ISO 9001; experience with IATF 16949, VDA 6.3, and automotive customer-specific requirements preferred.
• Experience with APQP, PPAP, PFMEA, control plans, process flow diagrams, MSA, SPC, Run-at-Rate, and pre-launch activities.
• Strong communication, presentation, project-management, and stakeholder-influence skills.
• A proven ability to develop engineering talent and build high-performing teams.

This position requires up to 30% travel to support manufacturing facilities, customer and supplier locations, production launches, audits, and strategic engineering initiatives.

Benefits

• Affordable medical, dental, and vision insurance plans, including an innovative global healthcare option for qualified participants.
• 401(k) with company match, fully vested from day one.
• Competitive PTO: 3 weeks of vacation + 9 company-paid holidays.
• On-site medical clinics: free for you and covered dependents.
• Teladoc: 24/7 access with no copay.
• Tuition reimbursement and professional development assistance.
• Discounts with HSM partners, including Dollywood Parks & Resort and Verizon Wireless.