Process Engineer

Description

Position Summary

The Process Engineer is responsible for developing, implementing, and continuously improving manufacturing processes for complex, close-tolerance components from contract review through first article and production. The role also supports controlled production readiness, risk-based process planning, and sustainable manufacturing process ownership as A1J scales its commercial aerospace and defense manufacturing capabilities.

The role develops complete manufacturing routings that define the sequence of operations, work centers, tooling, fixturing, materials, setup and run standards, inspection considerations, outside processing, and traceability requirements. The Process Engineer works cross-functionally with CNC Programming, Production, Quality, Supply Chain, and Estimating to ensure manufacturing processes are safe, capable, repeatable, cost-effective, and properly documented.

The position supports a high-mix precision manufacturing environment that includes CNC turning and milling, grinding, lapping, welding, cleaning, and outside special processes.

Primary Responsibilities

Manufacturing Process Planning

• Develop and maintain manufacturing routings for new and existing products, including operation sequence, work centers, setup/run standards, tooling, fixturing, materials, and outside processing.
• Determine the appropriate manufacturing sequence for close-tolerance features while considering datum integrity, distortion, material condition, accessibility, and downstream operations.
• Establish material requirements, blank sizes, material yield, and traceability controls.
• Define appropriate handling, identification, protection, and material-flow requirements throughout manufacturing.
• Maintain accurate ERP routing information to support scheduling, capacity planning, costing, and actual-versus-standard performance analysis.
• Maintain process documentation and revision control consistent with drawing revisions, engineering changes, and approved process improvements.

CNC Programming & Production Support

• Partner with CNC Programming to translate manufacturing-process requirements into executable machining strategies.
• Support tooling, fixture, work holding, probing, and setup-method development.
• Participate in process kickoff reviews and first article/prove-out activities for new or high-risk jobs.
• Capture actual setup and cycle times and update manufacturing standards as appropriate.
• Support standardization of tooling, setup practices, work instructions, and manufacturing methods across similar part families.
• Provide technical support to Production in resolving machining and process-related issues.

Quality & First Article Support

• Partner with Quality to ensure inspection planning aligns with the actual manufacturing sequence.
• Identify process-critical inspection points, irreversible operations, inaccessible features, and high-risk characteristics requiring in-process verification.
• Support interpretation of drawings, specifications, GD&T, tolerance stacks, and key/critical characteristics from a manufacturing perspective.
• Provide manufacturing-process information required for First Article Inspection and AS9102 documentation.
• Support development and analysis of process capability (Cp, Cpk, Ppk) for critical characteristics.
• Provide process expertise during nonconformance investigations, root-cause analysis, and corrective actions.
• Ensure approved process changes are communicated to Quality for evaluation of inspection-plan impact.

Continuous Improvement & Cost

• Analyze actual versus standard setup/run hours, scrap, rework, yield, and process performance.
• Lead projects to reduce setup time, cycle time, scrap, rework, and manufacturing cost.
• Identify and implement process improvements that increase throughput, capability, and repeatability.
• Support make-versus-buy decisions based on capability, capacity, cost, and risk.
• Provide manufacturing input to quoting and contract review, including process feasibility, estimated hours, tooling/fixture requirements, NRE, capacity, and technical risk.
• Support capital-equipment justification through capacity analysis, manufacturing requirements, and return-on-investment evaluation.
• Capture lessons learned and incorporate improvements into standardized manufacturing processes.

Production Readiness, Risk & Process Governance

• Coordinate cross-functional manufacturing readiness reviews before release, verifying routing completeness, material, tooling, fixtures, programming, inspection requirements, outside processing, and applicable customer specifications; obtain required functional approvals.
• Perform and document proportionate process-risk assessments for new, changed, and high-risk jobs, including critical features, irreversible operations, datum strategy, distortion, and potential failure modes.
• Evaluate and document proposed changes to routing sequences, work centers, tooling, fixtures, setup methods, and manufacturing processes; coordinate Quality review, FAI impact assessment, and customer approvals where required before implementation.
• Validate and maintain the technical accuracy of assigned JobBoss/ERP routings, operation descriptions, work centers, setup/run standards, and revision data; coordinate scheduling impacts with Planning and transaction accuracy with Production.
• Participate in selected first-piece and prove-out activities; document findings, validate setup/cycle assumptions, and close process-related issues before routine or repeat production.
• Develop reusable routing templates, standardized manufacturing methods, setup documentation, and lessons-learned records; monitor released processes and update controlled documentation following approved improvements.

Key Performance Indicators

• First Article / First-Pass Yield - Process works correctly before repeat production
• Actual vs. Standard Hours - Routing standards accurately reflect manufacturing performance
• Manufacturing Readiness / Process Release Quality - Assigned jobs released with required technical and cross-functional reviews complete
• Scrap & Rework - Reduce process-related quality losses
• Setup & Cycle Time - Improve manufacturing efficiency and capacity
• On-Time Routing Release - Engineering does not delay production release
• Routing Accuracy - ERP data supports planning, costing, and scheduling
• Process Improvement Savings - Quantifiable cost/capacity improvement
• Quote Estimate Accuracy - Improve feedback between actual manufacturing and estimating

Work Environment

• Ability to stand and walk throughout CNC and production areas for extended periods and lift tools, fixtures, parts, and materials weighing up to 40 pounds.
• Manual dexterity and visual acuity sufficient to operate equipment, use measuring instruments, read prints, inspect parts, and identify tool wear or process defects.
• Regular exposure to CNC equipment, cutting tools, coolant, chips, noise, moving machinery, and normal manufacturing conditions.
• Required use of appropriate PPE and compliance with all site safety requirements.
• Frequent interaction with production personnel, engineering, quality, customers, and executive leadership.
• May require extended hours to support customer deadlines, production demands, and operational initiatives.

Benefits

• Medical Insurance
• Dental Insurance
• Vision Insurance
• Life Insurance
• Paid Time Off
• 401(k) Retirement Plan
• 401(k) Employer Match

Requirements

Required Qualifications

• Bachelor's degree in Mechanical, Manufacturing, Industrial Engineering, or related technical discipline; equivalent hands-on manufacturing experience may be considered.
• 5+ years of manufacturing/process engineering experience in precision machining or a comparable high-mix manufacturing environment.
• Demonstrated experience developing manufacturing routings, process plans, and controlled manufacturing documentation.
• Strong understanding of CNC machining, tooling, fixturing, setup practices, and manufacturing process development.
• Ability to interpret engineering drawings, GD&T, CAD models, and technical specifications.
• Working knowledge of CAM software and CNC manufacturing methods.
• Experience supporting first article, inspection planning, root-cause analysis, and corrective action.
• Strong problem-solving, technical communication, and cross-functional leadership skills.
• Ability to spend significant time on the manufacturing floor supporting process development and production.

Preferred Qualifications

• Experience in AS9100 / ISO 9001 aerospace, defense, semiconductor, medical, or other regulated precision-manufacturing environments.
• Experience with multi-axis turning and 3-, 4-, and 5-axis milling.
• Experience with grinding, lapping, welding, cleaning, heat treatment, plating/coating, or other special processes.
• Familiarity with AS9102 First Article Inspection.
• Experience with Lean Manufacturing, Six Sigma, DOE, 8D, A3, or structured problem-solving methods.
• Fixture and tooling design experience using 3D CAD.
• Familiarity with CMM/metrology and process capability analysis.
• Experience supporting customer, regulatory, or third-party audits.