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Key Responsibilities and Required Skills for Manufacturing Process Engineer

💰 $ - $

EngineeringManufacturingProcess EngineeringIndustrial EngineeringContinuous Improvement

🎯 Role Definition

The Manufacturing Process Engineer designs, develops, implements, and optimizes manufacturing processes to ensure safe, cost-effective, high-quality, and repeatable production of products. This role partners with product engineering, quality, operations, maintenance, procurement and automation teams to scale prototypes into robust production processes, reduce cost-of-goods, increase throughput, and maintain compliance with regulatory and customer requirements. Ideal candidates demonstrate strong hands-on process development experience, statistical analysis capability (SPC/DOE), strong knowledge of DFx/DFM principles, and proven delivery of continuous improvement projects using Lean and Six Sigma methods.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Manufacturing Technician / Process Technician
  • Industrial Engineer
  • Quality Engineer / Production Engineer

Advancement To:

  • Senior Manufacturing Process Engineer
  • Manufacturing Engineering Manager / Continuous Improvement Manager
  • Plant Manager / Director of Manufacturing Engineering

Lateral Moves:

  • Quality Engineering (Supplier or Product Quality)
  • Automation / Controls Engineer
  • Product / Design Engineer

Core Responsibilities

Primary Functions

  • Lead end-to-end process development for new product introductions (NPIs) including process flow design, tooling specification, pilot builds, first article inspection, production validation and handover to operations to achieve target yield, cycle time and cost objectives.
  • Conduct detailed Process Failure Mode and Effects Analysis (PFMEA) and develop robust Control Plans and work instructions to mitigate risks, reduce escapes, and ensure sustained process capability across multiple production lines.
  • Design and execute statistically sound Design of Experiments (DOE) and controlled trials to identify process drivers, optimize process windows, and quantify relationships between material, machine, method and measurement variables for consistent product quality.
  • Implement Statistical Process Control (SPC) programs and manufacturing metrics (Cp, Cpk, Ppk) for critical-to-quality characteristics; analyze control charts and lead corrective actions to stabilize processes and improve capability.
  • Lead root cause analysis using structured methods (8D, A3, DMAIC) for recurring quality or production issues; define and implement corrective and preventive actions (CAPA) and verify effectiveness through data-driven follow-up.
  • Define equipment requirements, collaborate with suppliers and internal automation teams to specify/approve tooling, fixtures, gauges, robots and end-of-arm tooling; drive equipment commissioning, qualification and process acceptance testing.
  • Create and maintain detailed process documentation including standard operating procedures (SOPs), work instructions, process maps, routers, bill of process and inspection plans to ensure reproducibility and compliance with internal and external audits.
  • Partner with supply chain and procurement to assess manufacturability of purchased parts, qualify supplier processes, and transfer manufacturing processes to/from contract manufacturers while maintaining quality and schedule.
  • Lead cost reduction and productivity improvement initiatives using Lean methods (5S, Kaizen, value stream mapping, SMED) and Six Sigma projects to reduce scrap, labor content and cycle time while increasing throughput and overall equipment effectiveness (OEE).
  • Perform tolerance analysis, GD&T reviews and design-for-manufacture (DFM) assessments with product development teams to minimize rework, ensure assembly fit, and reduce downstream quality liabilities.
  • Manage scale-up for volume ramp: plan capacity, staffing, training, line balancing and material flow to meet production ramp targets while observing safety and quality metrics.
  • Develop test methods, sampling plans and automated inspection strategies (vision systems, in-line gauges) that integrate into manufacturing execution systems (MES) for real-time quality assurance and traceability.
  • Drive cross-functional pilot runs and production trials, collect and analyze throughput, yield and downtime data, and iterate process and tooling to achieve validated process performance prior to full-rate production.
  • Support product lifecycle changes by assessing impact of engineering changes on process capability, cost and schedule; update production processes and re-qualify as required.
  • Ensure compliance with regulatory requirements, industry standards (ISO, IATF) and customer-specific requirements through scheduled process audits, internal checks, and preparation for third-party assessments.
  • Mentor and train production personnel, supervisors and technicians on new processes, tooling changeovers, quality requirements and safety protocols; create training materials and competency assessments.
  • Evaluate and implement automation and robotics solutions to reduce manual operations, improve repeatability and lower unit costs while maintaining or improving quality and safety.
  • Conduct preventive maintenance reviews and collaborate with maintenance to ensure critical equipment uptime, develop maintenance plans, and identify spares and spare strategies to avoid production interruptions.
  • Use manufacturing data analytics (Minitab, Python, MATLAB) to visualize trends, build predictive models, and translate insights into prioritized process improvements and business cases.
  • Manage and control process-related CAPEX and prototype budgets: prepare cost-benefit analyses, vendor comparisons, and timeline estimates; oversee installation and commissioning to achieve ROI targets.
  • Facilitate cross-functional change control boards for process changes, ensuring documented risk assessment, validation plan, and communication to affected stakeholders and suppliers.
  • Lead continuous improvement events (Kaizen, gemba walks) and build a process-focused culture that rewards data-driven problem solving, safety compliance and measurable performance gains.
  • Coordinate with quality engineering and metrology to select, qualify and maintain measurement systems, perform gauge R&R studies and ensure measurement integrity for critical inspections.

Secondary Functions

  • Support ad-hoc production analysis and rapid troubleshooting during urgent production incidents, providing technical guidance to floor teams and coordinating containment actions.
  • Maintain and contribute to the department’s manufacturing knowledge base, lessons learned, and engineering change history to accelerate future NPI and sustainment activities.
  • Assist in supplier process assessments, incoming inspection improvements, and collaboration on corrective actions with external partners.
  • Participate in cross-disciplinary project teams, sprint planning, and agile-style delivery for NPI and process improvement projects, ensuring timely technical deliverables and stakeholder communications.
  • Support continuous monitoring of KPIs (yield, OEE, downtime, scrap %) and generate weekly/monthly reports for operations leadership and program management.

Required Skills & Competencies

Hard Skills (Technical)

  • Lean Manufacturing methodologies (Kaizen, 5S, VSM, SMED) — proven ability to lead and sustain improvements on the shop floor.
  • Six Sigma (Green Belt or Black Belt preferred) — demonstrated application of DMAIC and statistical tools for process improvement.
  • Statistical Process Control (SPC), process capability analysis (Cp, Cpk), and control chart interpretation.
  • Design of Experiments (DOE) and multivariate optimization techniques to characterize and tune manufacturing processes.
  • PFMEA, Control Plan development, SOP/Work Instruction authoring and change control.
  • CAD and engineering drawing literacy (SolidWorks, AutoCAD) plus GD&T competency for tooling and fixturing design.
  • Manufacturing automation and controls knowledge (robotics, PLCs, vision systems) and experience interfacing with MES/SCADA.
  • Measurement systems analysis and gauge R&R, experience specifying inspection equipment and automated metrology.
  • Hands-on tooling specification, fixture design, and vendor management for production equipment.
  • Data analysis tools: Minitab, JMP, Excel (advanced), and basic scripting/data manipulation in Python or MATLAB for analytics.
  • ERP/MRP system experience (SAP, Oracle, or equivalent) for BOMs, routings and production planning.
  • Process validation, product qualification and regulatory compliance (ISO 9001, IATF 16949 or industry-specific standards).
  • Cost and capacity modeling, labor standards development, and cycle time analysis.
  • Root cause problem solving methodologies (8D, 5 Whys, A3 thinking).

Soft Skills

  • Strong cross-functional collaboration and stakeholder communication — able to translate technical constraints into business impact for operations, program management, and supply chain.
  • Analytical mindset with a focus on measurable outcomes and data-driven decision making.
  • Project management skills — able to manage multiple concurrent projects, set priorities, and deliver on schedule with clear documentation.
  • Coaching and training aptitude — experience upskilling production teams and internal customers on new processes and quality expectations.
  • Adaptability and bias for action in high-change environments, particularly during product launches and production ramps.
  • Clear written and verbal communication skills for creating process documentation, FMEAs, presentations and executive summaries.
  • Attention to detail with strong organizational skills and the ability to manage technical documentation and compliance records.
  • Customer-focused orientation: able to interpret customer specifications and implement processes that meet or exceed requirements.
  • Leadership presence to facilitate Kaizen events, cross-functional problem-solving workshops and supplier negotiations.
  • Safety-first mindset and commitment to creating a hazard-free manufacturing environment.

Education & Experience

Educational Background

Minimum Education:

  • Bachelor's degree in Mechanical Engineering, Industrial Engineering, Manufacturing Engineering, Electrical Engineering, Materials Science, or equivalent technical discipline.

Preferred Education:

  • Master’s degree in Engineering or MBA with manufacturing emphasis or advanced certifications (Lean, Six Sigma Black Belt, PMP).

Relevant Fields of Study:

  • Mechanical Engineering
  • Industrial / Manufacturing Engineering
  • Materials Science and Engineering
  • Mechatronics / Electrical Engineering

Experience Requirements

Typical Experience Range: 3–8 years of hands-on manufacturing/process engineering experience in a high-mix or high-volume production environment.

Preferred:

  • 5+ years experience in process development, NPI, or manufacturing optimization, with at least one full product launch supported from pilot to full-rate production.
  • Demonstrated track record with Lean and Six Sigma projects that delivered measurable cost savings, yield improvements or productivity gains.
  • Industry experience in automotive, aerospace, medical devices, electronics, consumer products or heavy industrial manufacturing is a strong plus.
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