Position SummaryThe Manufacturing Process Engineer will work across the six metal manufacturing businesses within the United Stars portfolio to identify and implement opportunities that improve
safety, quality, delivery, lead times, and cost.
This is a hands-on manufacturing engineering position focused on identifying and solving process problems, improving manufacturing methods, eliminating waste, reducing cycle time and labor content, improving flow, and increasing the overall effectiveness of manufacturing operations.
The position will work directly with operating company leadership, engineering, operations, quality, maintenance, and production personnel to understand manufacturing processes, identify opportunities, develop solutions, and drive improvements through implementation.
The role will support improvement initiatives identified by the individual operating companies while also independently identifying opportunities where corporate involvement can create significant value. This may include:
- Improving manufacturing processes, methods, and work sequences
- Reducing cycle time and direct labor requirements
- Improving throughput, capacity, and delivery performance
- Reducing scrap, rework, and quality-related costs
- Improving material flow and plant layouts
- Identifying and implementing automation opportunities
- Improving machine utilization and process capability
- Introducing new equipment, technology, tooling, or manufacturing methods
- Developing and implementing standardized processes and best practices
- Leading capital projects associated with manufacturing improvements
Travel between United Stars operating companies is a regular and necessary part of the position. The role requires on-site presence for process evaluations, improvement projects, equipment run-offs, installations, commissioning, and other manufacturing activities. Travel requirements will vary based on project needs and may range from periodic trips of approximately one week per month to extended assignments of several consecutive weeks, with the expectation of returning home on weekends when practical.
Primary ResponsibilitiesContinuous Improvement & Process Engineering- Identify and implement opportunities to improve productivity, quality, cost, safety, capacity, and delivery.
- Analyze manufacturing processes, production data, cycle times, labor requirements, equipment utilization, and material flow to identify improvement opportunities.
- Develop and implement improved manufacturing processes, methods, layouts, routings, and work sequences.
- Identify and eliminate sources of waste, bottlenecks, downtime, excessive labor, scrap, rework, and unnecessary process steps.
- Work directly with operators, supervisors, engineers, and plant leadership to understand problems and develop practical solutions.
- Establish appropriate measurements and verify that implemented improvements produce the expected results.
- Identify successful processes, technologies, and practices within one operating company and facilitate their application at other facilities where appropriate.
- Apply Lean, Six Sigma, and other continuous improvement methodologies as appropriate to the problem.
Manufacturing Technology & Automation- Evaluate opportunities to improve manufacturing performance through automation, robotics, machine controls, tooling, fixturing, and other manufacturing technologies.
- Identify opportunities for new or improved equipment and manufacturing processes.
- Work with equipment manufacturers, integrators, tooling suppliers, and other outside resources to develop practical solutions.
- Evaluate the technical and economic feasibility of proposed improvements.
Capital Projects- Lead manufacturing-related capital projects from initial concept and feasibility through implementation.
- Develop project justifications including estimated investment, expected savings, capacity impact, payback, ROI, and other appropriate financial measures.
- Develop project requirements and coordinate equipment selection, procurement, installation, commissioning, and startup.
- Monitor projects to ensure that technical, financial, schedule, and performance objectives are achieved.
- Verify actual results following implementation and identify additional opportunities for improvement.
Corporate Engineering Support- Serve as a technical manufacturing resource to the United Stars operating companies.
- Participate in significant manufacturing improvement projects where additional engineering expertise or resources are required.
- Provide objective technical analysis for significant manufacturing and capital-investment decisions.
- Stay current with developments in metal manufacturing, automation, tooling, machining technology, and other technologies applicable to the United Stars businesses.
Qualifications Required- Bachelor's degree in Engineering, Manufacturing Engineering, or a related technical discipline; equivalent combination of education and significant manufacturing experience will be considered.
- Significant experience in metal manufacturing and manufacturing process engineering, with a strong background in metal cutting and machining.
- Extensive practical knowledge of multiple metal-cutting processes, including several of the following: turning, milling, grinding, broaching, hobbing, shaping, drilling, sawing, and related machining operations.
- Demonstrated experience improving manufacturing processes and achieving measurable improvements in productivity, cost, quality, capacity, or delivery.
- Strong understanding of machining fundamentals, including tooling, workholding, cutting parameters, cycle-time reduction, process sequencing, and manufacturing methods.
- Excellent ability to read and interpret complex manufacturing drawings and GD&T.
- Demonstrated ability to analyze manufacturing problems and develop practical, cost-effective solutions.
- Experience leading manufacturing improvement projects from concept through implementation.
- Mechanical and hands-on aptitude with the ability and willingness to spend significant time on the manufacturing floor.
- Demonstrated ability to work effectively with operators, production personnel, engineers, and plant leadership.
- Ability to work independently, prioritize multiple opportunities, and operate effectively with limited direction.
- Excellent communication, analytical, and project leadership skills.
- Proficiency with Microsoft Office applications.
Qualifications Desired- Lean Six Sigma Black Belt certification or demonstrated equivalent experience.
- Experience implementing automation, robotics, machine vision, or advanced manufacturing technologies.
- Experience with CNC machining and CNC programming.
- Experience with tooling development, fixture design, or process optimization.
- Experience with ERP/MRP systems and an understanding of manufacturing planning, routings, capacity, scheduling, and lead-time management.
- Experience with SolidWorks or equivalent engineering/design software.
- Experience developing capital expenditure justifications and financial analyses.
- Experience with preventive or predictive maintenance programs.
- Experience working in a multi-site or corporate manufacturing environment.
- Experience with welded stainless tube, stainless castings, or other specialty metal manufacturing processes is a plus.
What Success Looks LikeSuccess in this position will be demonstrated through
measurable improvements to the businesses, including:
- Reduced manufacturing cost and labor content
- Reduced cycle times
- Increased throughput and capacity
- Improved on-time delivery and manufacturing lead times
- Reduced scrap and rework
- Improved manufacturing quality and process capability
- Improved equipment utilization
- Successful implementation of automation and new manufacturing technologies
- Capital projects completed on time and achieving their expected financial and operational results
- Successful transfer of manufacturing best practices between operating companies
- A consistent pipeline of identified and implemented improvement opportunities
