Senior Process Engineer

Position Overview

Ultimate Staffing Services is actively seeking a highly skilled and experienced Senior Process Engineer to join a leading team in Durham, North Carolina. This pivotal role involves significant contributions to the lifecycle of a 1 million square foot manufacturing facility expansion, with responsibilities ranging from design and equipment specification through installation, commissioning, production startup, and scale-up to full capacity. The role will initially be based in Durham, NC, and is expected to move to Benson, NC.

Responsibilities

• Run engineering trials to determine optimal equipment recipes and operating windows. Own the parameter definition required to transition processes from development to stable, high-volume production.
• Identify the best ways to operate manufacturing equipment to maximize yield, improve throughput, and minimize scrap. Monitor OEE results and station cycle times to drive continuous improvement.
• Lead Gage R&R studies and capability studies (Cpk analysis) to ensure equipment and measurement systems are capable of meeting tight product specifications.
• Lead and own the PFMEA (Process Failure Mode and Effects Analysis) for designated process steps to proactively identify and mitigate product and process risks.
• Provide hands-on support during production startup, helping operators stabilize processes and eliminating early bottlenecks.
• Review physical product quality at the station level, mapping defects back to root causes in the machinery or process settings.
• Ensure compliance with safety, environmental, and quality standards across all process activities.
• Interact and travel to support equipment development reviews and Factory Acceptance Tests (FATs) as needed (estimated at
• Develop and manage deliverables including Risk Assessments, Process Flow Charts, Quality Control Plans, Standard Operating Procedures, and more.

Qualifications

• Bachelor's degree in Chemical Engineering, Materials Science, Industrial Engineering, Mechanical Engineering, or a related technical discipline with 5+ years of experience OR a Master's degree with 3+ years of experience.
• Deep expertise running DoEs (Design of Experiments), Gage R&R studies, and statistical process control (SPC) to optimize high-precision manufacturing processes.
• Expert-level experience authoring and developing standard manufacturing documents (PFMEA, Control Plans, Work Instructions, and Process Flows).
• Proven track record of designing and running on-floor production trials to dial in complex equipment parameters without causing excessive downtime.

Must be a U.S. Person due to required access to U.S. export-controlled information or facilities.

Preferred Qualifications

• Experience specifically in heavy industrial manufacturing, metallurgy, magnetics, or chemical processing.
• Six Sigma Green Belt or Black Belt certification.
• Familiarity with MES (Manufacturing Execution Systems) implementation and automated transaction mapping.
• Experience in highly regulated industries such as Defense (DoD), Aerospace (AS9100), or Automotive (IATF 16949).

Required Work Hours

Monday to Friday, 1st shift

Benefits

The position offers competitive pay ranging from $100,000 to $160,000 annually and is a supervisory role, providing an opportunity to lead and grow within a dynamic and innovative environment.

All qualified applicants will receive consideration for employment without regard to race, color, national origin, age, ancestry, religion, sex, sexual orientation, gender identity, gender expression, marital status, disability, medical condition, genetic information, pregnancy, or military or veteran status. We consider all qualified applicants, including those with criminal histories, in a manner consistent with state and local laws, including the California Fair Chance Act, City of Los Angeles' Fair Chance Initiative for Hiring Ordinance, Los Angeles County Fair Chance Ordinance, and San Francisco Fair Chance Ordinance.