Lead Process Engineer

Position Overview

Perform the following job duties in a premium metal credit card manufacturing environment, with a focus on high-quality production standards and precision-driven processes.

• Demonstrate expertise in ISO/IEC 7811-1, INCITS 440, and CQM quality standards, with a strong understanding of their application in metal card manufacturing and quality assurance processes.
• Oversee coating processes for stainless steel substrates, tailored for UV inkjet printing applications, including qualification and scale-up for production.
• Perform statistical analysis of manufacturing yields to identify performance gaps, drive continuous improvement initiatives, and strategically plan and deploy process enhancements to optimize yield and reduce production costs.
• Prepare and present technical proposals and improvement plans to senior leadership, championing initiatives that enhance product quality, reduce waste, and support strategic growth.
• Travel to vendor sites to perform detailed engineering audits and collaborate on developing supplier quality requirements that align with rigorous manufacturing and product excellence standards.
• Understand the end-to-end metal credit card manufacturing process, from raw material selection through final product delivery and lifecycle management.
• Use diverse manufacturing techniques including precision material assembly, thermal lamination, CNC machining, and advanced vision inspection systems to ensure high-quality, high-volume card production.
• Drive yield improvement projects, utilize advanced data-driven methods (SPC, FMEA, 5 Whys, Fishbone) to identify and eliminate root causes of scrap, rework, and process variation.
• Oversee and coordinate new product introduction (NPI) activities, including process validation, work instruction development, and ramp-up readiness.
• Collaborate with Quality, Maintenance, and Operations leadership to develop and execute strategic initiatives focused on cost reduction, efficiency, and throughput.
• Develop, review, and approve standard operating procedures, process documentation, and training materials for manufacturing staff.
• Implement Lean manufacturing and Six Sigma techniques to reduce waste and improve process control.
• Monitor and analyze key performance indicators (KPIs) for yield, cycle time, downtime, and quality, providing regular reporting and strategic action planning.
• Represent the process engineering function in audits, customer visits, and internal reviews as a technical subject matter expert.
• Ensure compliance with safety, quality, and regulatory standards applicable to manufacturing operations.
• Prioritize and manage multiple projects to ensure critical processes impacting business results are addressed.
• Ensure thorough documentation of existing and new processes, including progressive results, equipment parameters, and work instructions.
• Perform the foregoing using Lean, Six Sigma, SPC, and other process control methodologies, data analysis tools (Excel, Minitab, JMP, etc.) and manufacturing systems (MES, ERP).

• Requires a Bachelor's degree in Mechanical Engineering and 5 years of experience in job offered or 5 years of experience in the Related Occupation.

We offer a comprehensive benefits package designed to support your health, financial well-being, and work-life balance, including medical, prescription, dental, and vision coverage; FSA/HSA options; company-paid life and disability insurance; 401(k) with company match; paid time off (PTO) and holidays; annual bonus opportunities; an employee assistance program (EAP); and opportunities for career growth and advancement.

Compo Secure is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, or national origin. We are also an equal opportunity employer of individuals with disabilities and protected veterans.