Sr Process Engineer (Huntsville)

“ Please note: This position is located onsite in Fayetteville, TN, approximately 30 miles north of Huntsville and commutable from North Alabama communities. ”

Senior Process Engineer | Fayetteville, TN | Commutable from North Alabama

Key Assets Recruitment is partnering with a client company to identify an experienced Senior Process Engineer for a manufacturing operation in Fayetteville, Tennessee, just north of the Alabama state line and within commuting distance of the greater Huntsville/North Alabama area. This will be a full - time, on - site position and a direct hire with our client company.

This is a highly visible, hands-on engineering role for someone who enjoys getting out on the plant floor, solving complex manufacturing problems, and driving measurable improvements. You’ll take ownership of significant process optimization, continuous improvement, capital equipment, automation, and new-process introduction projects, while partnering closely with Production, Quality, Maintenance, EHS, and leadership.

Our client is looking for an engineer who can go beyond identifying problems—someone who can dig into the data, determine root cause, implement solutions, and ensure the improvements stick. You’ll also have the opportunity to provide technical leadership and mentor developing engineers and technicians.

The strongest candidates will bring 7+ years of process engineering experience in manufacturing, along with a solid background in Lean/Six Sigma, process controls, capital projects, and data-driven problem solving. Experience in a continuous-process manufacturing environment is needed.

Location: Fayetteville, TN — a realistic commute for candidates living in North Huntsville, Hazel Green, Meridianville and other northern Madison County communities.

What you'll do:

• Lead process improvement projects using Lean, Six Sigma, and other structured methods to reduce scrap, downtime, and cost while improving quality and throughput.
• Analyze and optimize production processes such as [wire drawing, cladding/bonding, annealing, and stranding].
• Lead root cause analysis on complex process and quality issues, and put corrective actions in place that stick.
• Develop process controls, monitoring systems, and KPIs to track performance and sustain improvements.
• Manage capital projects, including automation and equipment upgrades, from justification and scoping through startup, on time and on budget.
• Lead the introduction of new processes, products, and technologies into production.
• Partner with Production, Quality, Maintenance, EHS, and Sales to align improvements with business and customer needs.
• Mentor and train junior engineers and technicians.
• Ensure processes meet safety, environmental, and industry requirements.
• Bring outside best practices and new technologies into our operations.
• Perform other duties as assigned.

What we are looking for:

• Bachelor's degree in Mechanical, Chemical, Industrial, Materials, Metallurgical, or Manufacturing Engineering; Master's degree preferred.
• 7+ years of process engineering experience in a manufacturing environment, with a track record of measurable results.
• Hands-on experience with Lean, Six Sigma, and Kaizen; Green or Black Belt certification preferred.
• Experience with process control systems, automation (PLCs a plus), and statistical data analysis tools such as Minitab or JMP.
• Experience managing capital projects, including cost justification and vendor management.
• Ability to manage several projects at once and prioritize in a fast-paced plant setting.
• Clear communicator who works well with everyone from operators to senior leadership.
• Proficiency with Microsoft Office and CAD software; process simulation experience a plus.
• Continuous-process manufacturing experience needed. Metals a plus.