Job Title: Sr. Process Engineer – Assembly & Automation
Location: West Haven, CT
Department: Manufacturing / Operations
Job Type: Full-Time
Position Summary
We are seeking a highly motivated Process Engineer to lead and support our assembly operations with a strong focus on process optimization, automation, and Lean manufacturing. The ideal candidate will play a critical role in driving operational excellence, improving assembly line performance, and leading continuous improvement initiatives to enhance safety, quality, delivery, and cost.
Key Responsibilities
- Develop and optimize assembly processes, ensuring alignment with quality, productivity, and cost targets.
- Identify and implement automation opportunities (robotics, vision systems, material handling, etc.) to increase efficiency and reduce manual labor.
- Collaborate with cross-functional teams including design, quality, maintenance, and operations to launch new products and processes into production.
- Lead and facilitate continuous improvement initiatives using Lean tools such as Kaizen, 5S, Standard Work, SMED, Value Stream Mapping, and Root Cause Analysis.
- Analyze and resolve process issues through structured problem-solving (e.g., DMAIC, 8D, PDCA).
- Develop and maintain process documentation, including work instructions, process flow diagrams, PFMEAs, and control plans.
- Monitor KPIs such as cycle time, OEE, scrap, and downtime; identify trends and take corrective actions.
- Champion Lean culture within the organization by training, mentoring, and engaging team members at all levels.
- Evaluate new equipment and technologies; develop business cases and support capital projects from concept through implementation.
- Ensure compliance with safety, quality, and environmental standards in all process engineering activities.
Qualifications
Required:
- Bachelor’s degree in Mechanical, Industrial, or Manufacturing Engineering or related field.
- 5+ years of experience in process or manufacturing engineering, preferably in a high-volume assembly environment.
- Proven experience in automation integration and Lean manufacturing principles.
- Strong knowledge of assembly tooling, fixtures, and workstations.
- Proficiency in using engineering tools such as AutoCAD/SolidWorks, Excel (advanced), and statistical analysis software (e.g., Minitab).
- Solid understanding of manufacturing KPIs, Six Sigma basics, and process validation.
- Strong project management, communication, and leadership skills.
Preferred:
- Six Sigma Green or Black Belt certification.
- Experience with PLC programming, robotics, or MES systems.
- Experience working in cross-cultural or multi-site environments.
Work Environment
- Majority of work performed in a plant/manufacturing floor environment with exposure to production machinery, noise, and moving equipment.
- Occasional travel to suppliers or other company sites may be required.