Sr Process Engineer

Position: Process Engineer Continuous Improvement

Location: Morgantown, PA



Department: Continuous Improvement Melt Shop



Reports To: Continuous Improvement Manager



Classification: Exempt



Shift: Day Shift

Compensation: $90000 - 110000 + 1.5% quarterly earnings

Now Hiring: Process Engineer Continuous Improvement (Morgantown, PA)

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A confidential metals manufacturing company is seeking an experienced Process Engineer Continuous Improvement to support process control, quality, and continuous improvement initiatives within its melt operations. This position works closely with Manufacturing, Quality, Engineering, customers, and vendors to improve process performance, reduce nonconforming product, and implement sustainable manufacturing improvements.

1. Job Summary

The Process Engineer Continuous Improvement performs engineering duties associated with the control, optimization, and improvement of EB, PAM, and VAR melting processes. This position combines process engineering, quality support, statistical analysis, and Lean Six Sigma methodologies to improve process stability, product quality, and manufacturing performance.

The successful candidate will have 3 6 years of process engineering experience and demonstrated experience leading cross-functional improvement projects. This role operates with limited supervision and may also provide technical guidance or informal mentorship to junior engineers and co-ops.

2. Essential Duties & Responsibilities

Process Engineering & Control

• Provide engineering and process support for EB, PAM, and VAR melting operations.

• Implement and monitor Statistical Process Control (SPC) for critical melt processing parameters, including gun power, melt rate, pressure, and related variables.

• Implement and monitor SPC for critical product parameters, including chemistry and weight.

• Analyze process and product data to identify trends, variation, and improvement opportunities.

• Initiate and support implementation of new melting processes and manufacturing technologies.

Quality & Product Support

• Provide quality support for EB, PAM, and VAR products, including melt releases, heat records, product certification, and customer order reviews.

• Evaluate and disposition nonconforming product.

• Develop and issue Corrective Action Reports (CARs) and applicable Nonconformance Reports (NCRs).

• Assist with customer complaints and investigations involving product or process quality concerns.

• Support customer and internal audits and associated corrective actions.

• Maintain quality documentation, including procedures, forms, process recipes, and related records.

Continuous Improvement

• Lead and support continuous improvement projects focused on reducing nonconforming product, improving process stability, and increasing operational performance.

• Apply Lean Six Sigma methodologies to identify root causes and implement sustainable process improvements.

• Utilize manufacturing and quality data to drive improvement initiatives.

• Develop and implement cost-saving and process optimization measures.

• Support or implement Management of Change (MOC) activities associated with melting operations.

• Support Manufacturing Process Experiments (MPE) and evaluate results to determine process effectiveness.

Project Leadership & Collaboration

• Lead medium-to-large-scale engineering and continuous improvement projects.

• Develop and lead cross-functional teams that may include Manufacturing, Quality, Maintenance, customers, and vendors.

• Coordinate with operators, supervisors, engineers, and subject matter experts to implement process changes.

• Communicate technical findings, project status, and recommendations through presentations and reports.

• Provide technical guidance and informal mentorship to junior engineers and co-ops.

• Work independently toward established goals with limited supervision.

3. Qualifications

Required

• Bachelor's degree in Engineering or a related technical/STEM discipline, or equivalent technical education and experience.

• 3 6 years of experience in Process Engineering within a manufacturing environment.

• Lean Six Sigma Green Belt certification at minimum, with Black Belt certification or active progress toward Black Belt preferred.

• Experience applying continuous improvement and structured problem-solving methodologies.

• Working knowledge of Statistical Process Control (SPC).

• Experience analyzing manufacturing and process data.

• Proficiency with Microsoft Office Suite.

• Experience leading cross-functional engineering or improvement projects.

• Ability to work independently with limited supervision.

• Must meet applicable U.S. export and import control requirements.

Preferred

• Metals manufacturing or processing experience.

• Experience with EB, PAM, and/or VAR melting processes.

• Minitab or similar statistical analysis software experience.

• Lean Six Sigma Black Belt certification.

• Experience mentoring engineers, interns, or co-ops.

• Strong knowledge of manufacturing and customer specifications.

• Internal or external auditing experience.

• Experience with corrective actions, NCRs, and nonconforming product disposition.

Key Technical Skills

• Process Engineering

• Continuous Improvement

• Lean Six Sigma

• Statistical Process Control (SPC)

• Root Cause Analysis

• Minitab / Statistical Analysis

• Corrective Action (CAR)

• Nonconformance Management (NCR)

• Process Optimization

• Manufacturing Data Analysis

4. Physical Requirements

• Frequent standing, walking, sitting, talking, and hearing throughout the workday.

• Frequent use of hands for handling equipment, documentation, and computer-related tasks.

• Frequent reaching with hands and arms.

• Occasional stooping, kneeling, crouching, or crawling.

• Ability to occasionally lift and/or move up to 25 pounds.

• Visual ability including close, distance, color, peripheral, and depth perception.

5. Working Conditions

• Combination of office and industrial metals manufacturing environments.

• Regular interaction with Manufacturing, Quality, Engineering, customers, and vendors.

• Position requires adherence to established safety and environmental procedures and use of appropriate personal protective equipment.

• No direct supervisory responsibilities; however, the position may lead cross-functional project teams and provide informal technical mentorship.

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