Process Engineer

Flag Solutions (Morgantown PA, USA) Follow 4 hours ago

Contract Continuous Improvement Process Optimization Manufacturing Engineering ARC Statistical Software 90,000 USD

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Position: Process Engineer

Location: Morgantown, PA
Department: Continuous Improvement
Reports To: Continuous Improvement / Process Engineering Manager
Classification: Exempt
Shift: Day Shift; overtime and off-shift support as needed

Compensation: $76100 - $90000 + 1.5% quarterly earnings

Now Hiring: Process Engineer (Morgantown, PA)

FLAG's mission is to show our contractors & clients the best this industry can offer by upholding our principles of leadership, service, and exceptionalism.

A confidential metals manufacturing company is seeking a data-driven Process Engineer to support continuous improvement and process engineering initiatives within its manufacturing operations. This position will focus on improving production processes, equipment performance, process controls, and monitoring methods to increase process stability, quality, and throughput.

1. Job Summary

The Process Engineer is responsible for recommending, developing, and implementing sustainable improvements to manufacturing processes, equipment, and process monitoring methods. A primary focus of this role is improving production process stability through statistical analysis, process control, root cause investigation, and continuous improvement.

Working closely with Production, Quality, Maintenance, senior technical staff, and customers, the Process Engineer will analyze manufacturing data, implement control plans, support process experiments, and address quality and production challenges. This position requires a hands-on, analytical engineer who can effectively translate production data into sustainable process improvements.

2. Essential Duties & Responsibilities

Process Engineering & Manufacturing Support

Provide technical process support for EB, PAM, and VAR melting processes.
Analyze manufacturing processes and recommend improvements to increase process stability, quality, and throughput.
Support the implementation of new melting processes, manufacturing methods, and engineering technologies.
Partner with Production, Quality, and Maintenance teams to troubleshoot manufacturing and process-related issues.
Provide technical support to off-shift personnel and respond to production issues as required.

Statistical Process Control & Data Analysis

Implement and monitor Statistical Process Control (SPC) for critical melting parameters, including melt rate, pressure, EB gun power, and other key process variables.
Establish and monitor SPC methods for critical product and process parameters.
Analyze manufacturing and quality data to identify trends, variation, and opportunities for improvement.
Utilize statistical analysis to drive process improvements and establish control plans that sustain results.
Use Minitab or similar statistical software to support process analysis and improvement activities.

Continuous Improvement

Lead or support continuous improvement projects focused on reducing nonconforming product, improving process stability, and increasing throughput.
Develop and implement sustainable solutions to recurring manufacturing issues.
Support cost reduction and operational efficiency initiatives.
Apply data-driven problem-solving techniques to identify root causes and implement corrective actions.
Promote best practices across manufacturing and technical teams.

Process Change & Documentation

Support or implement Management of Change (MOC) activities associated with melting and manufacturing processes.
Support Manufacturing Process Experiments (MPE) and evaluate results to determine process effectiveness.
Develop, revise, and maintain process documentation, procedures, forms, control plans, and related records.
Ensure manufacturing processes remain aligned with established procedures and applicable specifications.

Quality & Customer Support

Assist with customer complaints, corrective actions, and investigations involving quality or process concerns.
Participate in customer and internal audits as required.
Support internal audit programs and corrective action activities.
Collaborate with Quality personnel to ensure process changes maintain product and specification requirements.
Provide technical information and support during customer-related investigations.

3. Qualifications

Required

Bachelor's degree in Engineering or a related technical discipline, or equivalent technical education and experience.
Strong understanding of manufacturing and process engineering principles.
Working knowledge of Statistical Process Control (SPC) and data-driven process improvement.
Proficiency with Microsoft Office Suite.
Strong analytical and technical problem-solving skills.
Ability to analyze manufacturing data and translate findings into actionable process improvements.
Ability to work effectively with Production, Quality, Maintenance, Engineering, and other cross-functional teams.
Ability to work independently and manage multiple technical priorities.
Ability to work overtime, provide off-shift support, and respond to production emergencies as needed.
Must meet applicable U.S. export and import control requirements.

Preferred

Two (2) or more years of industrial or manufacturing engineering experience.
Metals manufacturing or processing experience.
Experience with EB (Electron Beam), PAM (Plasma Arc Melting), and/or VAR (Vacuum Arc Remelting) processes.
Experience with Minitab or similar statistical analysis software.
Experience implementing and maintaining Statistical Process Control systems.
Knowledge of industry specifications and manufacturing quality requirements.
Experience with Management of Change (MOC) and Manufacturing Process Experiments (MPE).
Experience supporting continuous improvement and process optimization initiatives.
Internal or external auditing experience.

Key Technical Skills

Statistical Process Control (SPC)
Minitab / Statistical Analysis
Process Engineering & Optimization
Root Cause Analysis
Continuous Improvement
Process Control Plans
EB / PAM / VAR Melting Processes
Management of Change (MOC)
Manufacturing Process Experiments (MPE)
Manufacturing Data Analysis

4. Physical Requirements

Ability to frequently stand, walk, sit, talk, and hear throughout the workday.
Frequent use of hands for handling equipment, documentation, and computer-related work.
Frequent reaching with hands and arms.
Occasional stooping, kneeling, crouching, or crawling.
Ability to occasionally lift and/or move up to 35 pounds.
Ability to safely navigate and work within an industrial manufacturing environment.
Ability to perform work requiring close, distance, peripheral, and depth vision.

5. Working Conditions

Combination of office and industrial manufacturing environments.
Regular interaction with Production, Quality, Maintenance, and Engineering personnel.
May require work outside normal business hours to support production personnel, troubleshoot problems, or respond to operational emergencies.
Required to follow all applicable safety and environmental procedures and use appropriate personal protective equipment.
No supervisory responsibilities.

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