Senior Process Engineer

The Senior Process Engineer is responsible for driving operational excellence across a high-volume, highly automated manufacturing facility. This role provides technical leadership for manufacturing processes, equipment optimization, new product introductions, and large-scale continuous improvement initiatives to achieve world-class safety, quality, delivery, and cost performance.

The Senior Process Engineer leads cross-functional projects from concept through implementation, develops standardized manufacturing processes, and serves as a technical mentor to Process Engineers and Operations teams. This position partners closely with Operations, Maintenance, Quality, Automation, Supply Chain, and customers to improve manufacturing capability while supporting production performance and business objectives.

This is an onsite role in our Mt. Juliet TN facility with a schedule of Monday - Friday, 8AM – 5PM.

What will be my duties and responsibilities in this job?

Manufacturing Process Leadership

• Provide technical leadership and engineering support for all production operations.
• Develop, optimize, and standardize manufacturing processes to improve safety, quality, productivity, and cost.
• Design and maintain manufacturing work instructions, process documentation, and standard operating procedures.
• Establish best practices that improve process consistency and manufacturing reliability.
• Support new product introductions, equipment launches, and production transfers.

Project Management

• Lead complex, cross-functional capital and operational improvement projects.
• Develop project timelines, budgets, resource plans, launch curves, and risk mitigation strategies.
• Create project dashboards and tracking systems to ensure milestones, deliverables, and financial targets are achieved.
• Coordinate activities between Engineering, Operations, Quality, Automation, Supply Chain, Maintenance, and external suppliers.
• Present project status and business results to plant leadership.

Continuous Improvement

• Lead Lean Manufacturing, Six Sigma, Kaizen, and Value Stream Mapping initiatives throughout the facility.
• Identify opportunities to reduce manufacturing cost, improve throughput, eliminate waste, and increase equipment utilization.
• Utilize data analytics to identify process bottlenecks and prioritize improvement opportunities.

Root Cause Analysis & Problem Solving

• Lead structured problem-solving activities utilizing:
  • DMAIC
  • 8D
  • 5 Why
  • Fishbone Analysis
  • FMEA
• Investigate manufacturing failures, field returns, and customer complaints.
• Validate corrective and preventive actions (CAPA) to eliminate recurring issues.
• Support production during critical downtime events and major quality issues.

Data Analysis

• Analyze manufacturing KPIs including:
  • Overall Equipment Effectiveness (OEE)
  • First Pass Yield (FPY)
  • Throughput
  • Cycle Time
  • Scrap
  • Rework
  • Labor Efficiency
  • Cost per Unit
  • Capacity Utilization
• Utilize statistical analysis and manufacturing data to drive operational decisions.
• Develop reports and dashboards using Excel, Power BI, or similar analytical tools.

Cross Functional Leadership

• Partner with Production, Maintenance, Automation, Quality, Materials, Supply Chain, Product Engineering, and Customers to achieve operational objectives.
• Coordinate with suppliers on component issues and alternate material qualifications.
• Support manufacturing readiness during new product launches.
• Lead engineering reviews and communicate technical recommendations to leadership.

Coaching & Technical Leadership

• Mentor Process Engineers
• Coach manufacturing supervisors and production teams on Lean Manufacturing principles.
• Provide technical guidance during equipment startups and process improvements.
• Lead engineering knowledge-sharing and technical training sessions.

What are the requirements needed for this position?

• Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, Electrical Engineering, or related engineering discipline
• 3+ years of manufacturing engineering experience in a high-volume manufacturing environment
• Experience leading large cross-functional manufacturing projects
• Strong project management experience with budgets, schedules, and resource planning
• Demonstrated experience in Lean Manufacturing and Six Sigma methodologies
• Experience with highly automated manufacturing systems
• Strong analytical and statistical problem-solving skills
• Proficient with Microsoft Excel, Word, PowerPoint, and Project
• Experience using AutoCAD for manufacturing layouts
• Excellent communication and leadership skills

What other skills/experience would be helpful to have?

• Experience in consumer electronics, wireless devices, or electronics refurbishment.
• Experience in high-volume automated manufacturing facilities.
• Lean Six Sigma Green Belt required; Black Belt preferred.
• Knowledge of Statistical Process Control (SPC), Minitab, and process capability analysis.
• Experience supporting robotics, vision systems, conveyors, and automated material handling.
• Power BI or advanced manufacturing analytics experience.
• Experience supporting New Product Introduction (NPI) and product launches

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