Senior Process Engineer – Greenfield, MA

The Senior Process Engineer takes full ownership of advanced processes and large, multi-part programs. You’ll architect CNC programs and work-holding, validate processes via robust inspection (including CMM), tune cycle time, and harden quality at the source. You’ll also lead cross-functional projects, mentor engineers/technicians, and drive automation/robotics where it makes sense.

Rate: $110,000 – 150,000

Key Responsibilities

Build & Own Core Systems

• End-to-End Process Ownership: Design, simulate, and validate machining processes (mill/lathe/5-axis) from concept through sustained production.

• CNC Programming & Prove-Out: Create advanced toolpaths; optimize feeds/speeds, tool life, MRR, and cut strategy; standardize post and program structure.

• Work-Holding/Tooling Architecture: Design modular, low-deflection fixtures; select and develop custom cutting tools; standardize setups to reduce operator dependency.

• Inspection Strategy & Control: Define in-process and final verification plans (incl. CMM programs); align with ASME Y14.5 and customer standards; tighten feedback loops to operators.

• Documentation & Change Control: Author routings, control plans, setup sheets, and standard work; execute ECNs and revision control with discipline.

Technical Ownership

• Metrology & Quality: Deep use of CMM, profilometry, micrometers, indicators; build error-proofing (poka-yoke), SPC, and capability monitoring into the process.

• Automation/Robotics Integration: Evaluate and integrate cobots, palletization, probing, in-machine measurement, and lights-out strategies where justified.

• Root Cause & Corrective Action: Lead complex troubleshooting; execute 8D/5-Whys; lock in fixes and verify effectiveness.

• DFM & Cost: Partner with Design/Production to de-risk features, reduce cycle time, tool spend, and scrap/rework without compromising quality.

Collaboration & Leadership

• Mentor & Uplevel: Coach Process Engineers/techs on CNC, fixturing, inspection, and problem solving; set coding and documentation standards.

• Cross-Functional Leadership: Align Production, Quality, and Planning on capacity, constraints, and launch ramps; provide crisp status and risk management to stakeholders.

• Customer/Supplier Interface: Support technical reviews, FAIs, and capability discussions; translate customer requirements into shop-ready processes.

Qualifications

• 8+ years in precision machining process engineering (multi-axis mill/turn; high-precision components).

• Expert CAD/CAM (e.g., SolidWorks + Mastercam/Fusion/HyperMill/Esprit/UG); strong post and simulation discipline.

• Proven CMM programming/operation; fluent in ASME Y14.5 (GD&T) and feature capability.

• Hands-on with Fanuc/Siemens/Heidenhain/Haas controls; advanced probing and macros.

• Demonstrated results in cycle-time reduction, FPY improvement, and scrap/cost reduction.

• Strong project leadership: plans, milestones, risk/mitigation; closes loops—no loose ends.

Nice-to-Have

• Experience with automation/robotics, pallet systems, and lights-out machining.

• Exposure to additive/3D printing for fixturing or prototype flow.

• ASQ/lean credentials (e.g., LSS Green/Black Belt), Minitab/SPC proficiency.

• ERP/MES/QMS (e.g., Epicor) experience.

Education

• BS in Mechanical/Manufacturing/Industrial Engineering (or equivalent hands-on expertise).

Tools & Systems You’ll Use/Own

• CAD/CAM (SolidWorks + Mastercam/Fusion/etc.), verification/simulation.

• Metrology: CMM software, profilometer, height gages, custom gaging.

• Controls/Automation: Probing, macros, cobots/pallet systems where applicable.

• Analytics: SPC, capability (Cp/Cpk), Minitab (or equivalent).

• ERP/QMS: Routings, travelers, ECNs, FAI/PPAP artifacts.

Success Metrics

• ≥ 15–30% cycle-time reductions on target families within 6–12 months.

• First-Pass Yield (FPY) and OEE trending up; scrap/rework and tool spend trending down.

• On-time launch of NPI and ECN changes; stable Cpk on key features.

• Documented standards (programming, fixtures, setups) adopted across cells

Rate: $110,000 – 150,000

8+ years in precision machining process engineering (multi-axis mill/turn; high-precision components). Expert CAD/CAM and proven CMM programming and operation is required.