Process Engineer

Process EngineerThe Process Engineer is the technical owner for assigned aerospace plating and finishing processes and is responsible for developing robust, repeatable and specification-compliant methods for precision machined components. This position bridges Engineering, Quality and Operations and must combine practical shop-floor plating knowledge with disciplined aerospace documentation. The engineer will improve process capability, develop technique sheets and master routings, solve chronic quality problems, support new-product introduction and ensure operators have clear, controlled instructions rather than relying on tribal knowledge.Essential ResponsibilitiesProvide technical ownership and continuous improvement for hard chrome plating, cadmium plating, electroless nickel, masking, Chemfilm/chemical conversion coating, passivation, Nital Etch and associated cleaning, activation, stripping, baking and surface-preparation operations.Develop, validate and maintain detailed process/technique sheets and master routings for existing and new aerospace products, including operation sequence, specification/revision, critical parameters, masking boundaries, tooling, inspection points and required records.Translate customer drawings, purchase orders and aerospace specifications into clear, executable shop-floor instructions in partnership with Planning and Quality.Engineer plating methods for precision machined parts with attention to dimensional build-up, plating allowance, ID/OD requirements, runout, edge effects, current density, anode design, racking/fixturing and post-plate machining/grinding considerations.Develop and optimize masking methods, plugs, fixtures, racks, auxiliary anodes, thieves/shields and other tooling needed for repeatable plating results.Establish and control critical process parameters including bath chemistry, temperature, current density, amperage, voltage, plating time, agitation, filtration, solution movement and rectifier capability.Perform process capability and root-cause analysis for adhesion failures, thickness variation, burning, pitting, nodules, roughness, porosity, corrosion/salt-spray failures, hydrogen-embrittlement risk and other special-process defects.Partner with laboratory/chemical-control personnel on bath analysis, additions, contamination control, tank maintenance and corrective actions.Support Nadcap Chemical Processing readiness, audits, corrective actions, objective evidence and compliance to approved procedures and customer requirements.Support AS9100 implementation through process risk analysis, configuration/document control, change management, verification/validation, control of nonconforming output and objective evidence.Support NDT interfaces where process sequences require Magnetic Particle or Liquid Penetrant inspection before/after processing.Lead new-product introduction and first-article/process-readiness reviews; identify technical risk before releasing production.Establish standard times and process assumptions with Operations/Estimating using actual shop data to improve quoting, capacity planning and job costing.Dixon Hard Chrome | Aerospace Special Processing | Quality • Delivery • Operational ExcellenceDesign or specify process equipment improvements including rectifiers, filtration, agitation, pumps, heating/cooling, tanks, tooling and instrumentation.Train and mentor plating technicians, maskers, supervisors, planners and inspectors on process requirements and technical fundamentals.Lead structured corrective action using 5-Why, fishbone, DOE/SPC or other appropriate analytical methods and verify effectiveness.Drive first-pass yield, process capability, cycle-time reduction, reduced rework/scrap and improved repeatability.Support customer/OEM technical reviews, frozen planning, specification interpretation and process approval activities.Maintain technical discipline around current specification revisions and ensure engineering changes are reviewed before implementation.Required Qualifications5+ years of process/manufacturing engineering experience in aerospace metal finishing, electroplating, chemical processing or a directly comparable special-process environment.Hands-on technical knowledge of hard chrome plating and cadmium plating is required; strong experience with electroless nickel, masking and aerospace chemical processing is highly desirable.Working knowledge of Chemfilm/chemical conversion coating, passivation and Nital Etch processes; candidate must be capable of rapidly owning these process families.Experience processing precision machined aerospace components where plating thickness, dimensional tolerance, masking boundaries and post-processing are critical.Demonstrated ability to interpret aerospace drawings, specifications, process standards and customer requirements and convert them into controlled manufacturing instructions.Knowledge of plating chemistry, electrochemistry, current density, rectification, anode/cathode relationships, solution control, agitation, filtration and process troubleshooting.Experience developing technique sheets, work instructions, routings, process plans or equivalent controlled manufacturing documentation.Working knowledge of Nadcap Chemical Processing expectations and aerospace QMS discipline.Strong root-cause analysis, statistical/problem-solving and technical-writing skills.Ability to work directly on the manufacturing floor with technicians and supervisors and translate engineering requirements into practical methods.Preferred QualificationsBachelor's degree in Chemical Engineering, Materials Engineering, Metallurgical Engineering, Mechanical Engineering or related technical discipline; directly relevant plating engineering experience may be considered.Experience with Client, AMS, MIL, ASTM, customer/OEM special-process specifications or comparable aerospace requirements.Experience with AS9100 implementation or maintenance.Experience supporting Nadcap Chemical Processing audits.Lean Six Sigma Green Belt, DOE/SPC experience or similar process-improvement training.Experience with ERP routings, Power BI, Minitab or comparable analytical/manufacturing systems.Key Performance IndicatorsFirst-Pass Yield / Process Defect ReductionRework and Scrap ReductionTechnique Sheet / Master Routing Completion and AccuracyProcess Capability / Parameter ControlNew-Product Introduction ReadinessCorrective Action EffectivenessDixon Hard Chrome | Aerospace Special Processing | Quality • Delivery • Operational ExcellenceNadcap / AS9100 Technical ComplianceCycle-Time and Throughput ImprovementStandard-Time / Job-Cost AccuracyTechnician Training and Process Knowledge TransferLeadership / Working ExpectationsThis is a hands-on, floor-visible position. The successful candidate is expected to lead with urgency, technical credibility, accountability, disciplined follow-through, and a strong commitment to safety, quality, delivery, cost, and continuous improvement.