Senior Process Engineer (Gear & Spline)

(Aerospace & Defense Manufacturing setting)

Location: CMI Group - Tempe, AZ 85281

Shift: Full time, day shift - On-site required, not a remote position.

Due to the nature of work performed within our facilities, U.S. citizenship or Valid Permanent Resident status is required.

Position Summary:

CMI Group is seeking a Senior Process Engineer to own and advance our gear, spline, and shaping manufacturing processes. This role will develop, document, and continuously improve manufacturing processes for complex gear and spline components used in commercial, military, and business jet platforms - driving quality, throughput, and cost performance from raw material through final inspection.

What You'll Do
• Develop and optimize manufacturing processes for gear shaping, spline rolling/shaping, hobbing, and related gear-form operations on aerospace hardware
• Create and maintain process documentation: routers, work instructions, setup sheets, and CNC programs in coordination with programming/manufacturing engineering
• Select and specify tooling, fixturing, and cutting parameters for gear shapers, hobbers, and CNC gear-generation equipment
• Troubleshoot process and quality issues on the shop floor (tooth form, lead, profile, runout, surface finish) and drive root-cause corrective action
• Support new part introduction (NPI) and first-article inspection (FAI/AS9102) for new gear and spline programs
• Partner with quality engineering on non-conformances, MRB dispositions, and continuous improvement of AGMA-rated tolerances
• Drive lean manufacturing and continuous improvement initiatives to reduce cycle time and scrap
• Collaborate with tooling suppliers, program management, and customer engineering on process capability and DFM feedback
• Support capital equipment justification and qualification for new gear-cutting and finishing technology

What You'll Need
• Bachelor's degree in Mechanical, Manufacturing, or Industrial Engineering (or equivalent hands-on experience in lieu of degree).
• 5+ years of process engineering experience specifically in gear, spline, and shaping manufacturing (shaping, hobbing, grinding, or rolling) general machining process experience without direct gear/spline experience will not meet this requirement
• Working knowledge of gear geometry and inspection (involute profile, lead, pitch, runout) and familiarity with AGMA standards
• Experience with CNC programming or process documentation in a machining environment
• Understanding of GD&T and ability to read complex aerospace engineering drawings
• Experience in an AS9100-certified manufacturing environment
• Strong root-cause/corrective-action and process-capability (Cp/Cpk) skills
• Direct experience with gear shapers (Fellows, Lorenz, Mitsubishi, or similar), hobbing machines, or spline rolling equipment
• Comfortable working on the shop floor alongside machinists and quality inspectors, not just at a desk

Nice to Have
• Experience with CMM programming/inspection for gear features
• Background in exotic aerospace alloys (titanium, nickel-based superalloys, stainless)
• Six Sigma / Lean certification

Work Environment
• On-site role across CMI Group's Phoenix-area manufacturing facilities
• Regular time on the production floor in an active machine shop environment (PPE required)
• Standard business hours with occasional flexibility to support production schedules

Physical Requirements:

• Ability to remain in a stationary position (sitting or standing) for extended periods when working at a computer.
• Ability to move throughout the production floor to observe workflow and communicate with production teams.
• Ability to occasionally lift or move materials, documents, or small components up to approximately 25 pounds.
• Ability to work safely in a manufacturing environment with noise, machine activity, and required PPE.
• Ability to communicate clearly in person, over the phone, and via electronic communication.
• Ability to perform fine-motor tasks such as handling documents and entering data.

Team oriented company with top paying wages and benefits in the valley in regards to the Aerospace Industry. To qualify for consideration, all candidates must be able to work 40+ hours per week in a fast paced, high-demand, quality environment. All candidates must also have sufficient verbal and written communication skills as well as good problem solving skills.

CMI Group is equal opportunity employer providing competitive wages and benefits. Medical, dental, vision, disability and life insurance available. 401(k) with company match.