Process Engineer

Description

Position Summary:

The Process Engineer is responsible for improving operational efficiency, ensuring product quality, and maintaining safety and environmental standards. This role covers supplier quality management, production support, safety coordination, and process optimization. The engineer will analyze workflows, implement operational solutions, develop work instructions, and manage quality inspections to ensure compliance with industry standards. The position requires collaboration with teams across Engineering, Manufacturing, HR, and Purchasing to resolve product design, production, and process issues while leading efforts to reduce waste and improve worker efficiency. Travel is required to support supplier development, customer site visits, and production troubleshooting.

Duties and Responsibilities:

Process Improvement:

• Analyze workforce utilization, facility layout, and production processes to identify areas for improvement.
• Develop business process solutions, create Bill of Materials (BOMs), and maintain accurate product structures in manufacturing software.
• Establish and maintain labor standards, process routings, and comprehensive work instructions for all production processes.
• Drive the Document Change Order (DCO) and Software Change Order (SCO) processes to ensure timely implementation of updates.
• Recommend methods to improve worker efficiency, reduce material waste, and optimize equipment usage.

Production Support:

• Analyze and track production-related quality issues, conducting root cause investigations to resolve them.
• Lead corrective action plans (CAPs) to eliminate production defects and facilitate bi-weekly corrective action meetings.
• Ensure final product quality by reviewing Final Acceptance Testing (FAT) sheets.

Product Reliability:

• Collaborate with design teams to ensure reliability and maintainability are incorporated into new product designs.
• Conduct initial and ongoing product qualification tests to maintain product standards and quality throughout the lifecycle.

Supplier Quality:

• Create and update inspection plans for incoming products, including first article inspections.
• Address product-related issues with suppliers through Supplier Corrective Action Requests (SCARs).
• Monitor and report on supplier performance, ensuring they meet quality standards.
• Qualify new suppliers and ensure they comply with KSI’s quality expectations.

Quality Assurance:

• Develop test procedures, quality inspection protocols, and reporting systems (e.g., SPC) to ensure product consistency.
• Conduct and/or oversee quality reviews to address performance issues, working closely with Engineering, Manufacturing, and Purchasing teams to resolve product defects.
• Ensure that product designs, materials, and production operations align with quality standards.

Safety Coordination:

• Serve as the primary contact for resolving safety issues and investigating incidents.
• Work with HR to ensure proper safety training, implement corrective actions from safety audits, and maintain environmental compliance.
• Organize safety meetings, monitor safety incentive programs, and contribute to Return to Work (RTW) plans.

Supervisory Responsibilities:

May oversee one Document Control Specialist and provide guidance to production personnel involved in quality inspections.

Physical and Mental Demands:

• Regularly sit, stand, walk, lift, bend, and reach. Ability to lift up to 60 pounds and occasionally move heavier objects with assistance.
• Perform complex mathematical calculations, analyze both qualitative and quantitative data, and write detailed technical documentation.
• Capable of working evenings and weekends as required to meet production deadlines.

Working Conditions:

• Typical office environment with occasional work on the production floor.
• Eight-hour workdays, five days a week, with flexibility to handle urgent or extended work hours.

Travel:

Up to 20% travel is required for supplier development, customer site visits, and production troubleshooting, including domestic and occasional international travel via car or airplane.

Qualifications

Education and Experience:

• Bachelor’s degree in process engineering, industrial engineering, manufacturing engineering, or a related discipline.
• 3 years of relevant experience in a process or manufacturing engineering role (e.g., Process Engineer, Quality Engineer, Supplier Quality Engineer).
• Experience in concurrent engineering processes, ISO9000 implementation, Lean/Six Sigma methodologies, and safety program coordination.

Skills:

• Proficient in Microsoft Office (Excel, Word) and manufacturing software (e.g., EPICOR, Access, 3D modeling).
• Strong knowledge of Quality Control Systems, statistical techniques, and root cause analysis.
• Excellent problem-solving, interpersonal, and communication skills, with the ability to interact effectively with all levels of the organization.
• Capable of interpreting technical documents, safety protocols, and process flows.