Process Engineer

Position Overview: We are seeking a hands-on and detail-oriented Process Engineer to join our dynamic manufacturing operations team. This role is critical in supporting yield improvement, day-to-day production troubleshooting, and new product introduction (NPI) within a fast-paced 24/7 high-volume production environment. You will work directly on 1st shift (8:30AM – 5PM) to ensure optimal performance of processes, effective support to production teams, and smooth onboarding of new products.

This position is an excellent opportunity for engineers looking to make a significant impact in advanced manufacturing operations, supporting blue-chip customers with world-class standards for quality and delivery.

The Process Engineer will be expected to work on-site five days a week in our Somerset, NJ office.

Key Responsibilities:

• Provide real-time process support for production teams on the afternoon shift, ensuring minimal downtime and swift issue resolution.
• Analyze and improve manufacturing yields, identifying root causes of scrap, rework, and process variation through data-driven methods (e.g., SPC, FMEA, 5 Whys, Fishbone).
• Lead or support new product introduction (NPI) activities, including process validation, work instruction development, and ramp-up readiness.
• Collaborate with cross-functional teams (Quality, Maintenance, Operations) to drive continuous improvement initiatives focused on cost, efficiency, and throughput.
• Develop and maintain standard operating procedures, process documentation, and training materials for manufacturing staff.
• Support implementation of Lean manufacturing and Six Sigma techniques to reduce waste and improve process control.
• Monitor key performance indicators (KPIs) for yield, cycle time, downtime, and quality, with regular reporting and action planning.
• Participate in audits, customer visits, and internal reviews as a technical subject matter expert for assigned process areas.
• Ensure compliance with safety, quality, and regulatory standards applicable to manufacturing operations

Other Important Responsibilities:

• Consistently demonstrate the ability to prioritize tasks to ensure most critical processes impacting business results are being addressed.
• Thorough documentation of existing processes and new process development, inclusive of progressive results, specific equipment parameters and work instructions where appropriate.
• Other miscellaneous duties as assigned.

Qualifications:

• Bachelor's degree in Manufacturing, Mechanical, Industrial, or Chemical Engineering (or equivalent field).
• A minimum of 5 years (or more) of experience in a high-volume manufacturing environment (preferably supporting 24/7 operations).
• Proven experience in yield improvement, root cause analysis, and process troubleshooting.
• Familiarity with NPI processes, including process validation and production readiness.
• Strong working knowledge of Lean, Six Sigma, SPC, and other process control methodologies.
• Proficiency with data analysis tools (Excel, Minitab, JMP, etc.) and manufacturing systems (MES, ERP).
• Excellent communication and collaboration skills across shifts and cross-functional teams.
• Willingness to work on the weekends or afternoon shift (3 PM – 11 PM) and occasionally support coverage across other shifts as needed.
• Experience in regulated manufacturing (e.g., automotive, aerospace, electronics, or medical device).
• Six Sigma Green Belt or Lean certification.
• Hands-on experience with automation systems, sensors, or high-throughput equipment.

Physical requirements and work environment:

• Must be able to lift 20 lbs;
• Must be able to sustain office work for 8+ hours per day including the following:
• Sitting in an office chair
• Typing
• Reaching for the telephone
• Standing at office equipment
• Hearing for phone use
• Sight for computer use
• Must be able to sustain factory work as needed including the following:
• Standing at machinery
• Reaching and pulling to operate machinery
• Sight for machinery operation
• Walking through shop
• Office environment is of moderate noise level.
• Shop noise levels are such that protective ear-coverings are recommended.