Job TitleGear Machining Process Engineer
Overview / Summary We are seeking an experienced Gear Machining Process Engineer to support manufacturing process engineering activities related to gear machining operations. This role is responsible for driving continuous improvement initiatives, supporting production launches, ensuring quality compliance, and optimizing manufacturing processes to improve safety, quality, and productivity.
Key Responsibilities - Support manufacturing process engineering activities for gear machining operations.
- Drive continuous improvement in safety, quality, and productivity.
- Complete PPAP quality launch documentation.
- Apply engineering principles and analytical techniques to establish and continuously improve manufacturing processes and products.
- Develop action plans to investigate and prioritize open issues and verify corrective actions on internal and supplier processes.
- Lead and conduct process audits to ensure process discipline and compliance with established guidelines.
- Conduct ergonomic evaluations and implement corrective actions as required.
- Create process documentation and work instructions supporting quality methods and manufacturing processes.
- Deliver capable processes and tooling for gear machining operations.
- Lead variability reduction and lean manufacturing initiatives.
- Ensure compliance with plant, corporate, governmental, and environmental standards.
- Support ISO 14001 compliance activities, including internal auditing requirements.
- Identify throughput constraints and drive root-cause improvements to achieve production targets.
Required Qualifications - High School Diploma or GED.
- 5+ years of related manufacturing engineering experience.
- Experience with lean manufacturing principles.
- Experience in manufacturing engineering and manufacturing processes.
- Strong leadership, communication, interpersonal, and team-building skills.
Preferred Qualifications - Bachelor's Degree.
- Gear manufacturing experience.
- Understanding of hypoid bevel gear processes, including blanking, milling, grinding, heat treat, shot peening, and lapping.
- Experience with quality assessment tools such as QDAS and Minitab.
- Experience with Klingelnberg P40 and Gleason Nano Gear CMM systems.
- Lean Manufacturing and Six Sigma experience.
- Experience with corrective action and problem-solving methodologies including 8D and 5 Why.
- Knowledge of Lean tools including 5S, Kanban, Poka-Yoke, and Value Stream Mapping.
- Experience with DMAIC and DMADV (DFSS) project methodologies.
- Experience with FMEA, PPAP, and Design of Experiments (DOE).
- Strong oral and written communication skills.
- Direct experience with round parts machining operations.
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