Process Engineer

Charter Wire is hiring a Process Engineer!

Job Summary:

Provide technical leadership and process expertise within Operations to continuously improve the safety, quality, yield, variation and throughput of manufacturing processes and equipment. Spend time on the floor and use process knowledge, data, structured troubleshooting and testing to identify root causes, develop and validate improvements, and sustain results across shifts. Work cross-functionally to implement new products, materials, equipment and processes, address non-conformances and customer corrective actions, and solve a broad range of operational issues.

Position specifics:

• Location:
  
  Northwest Milwaukee
• Schedule:
  
  First Shift, Monday-Friday, supporting a 24/5 operation. Occasional flexibility to meet with team members during off-shift hours or provide support by phone may be required.
• Applicants must be authorized to work for any employer in the U.S. Charter Manufacturing is unable to sponsor for employment visas at this time.

Key responsibilities:

• Observe manufacturing processes on the floor, analyze performance data, identify recurring losses, and lead structured troubleshooting with Operations, Maintenance, Tool Room, and Quality. Use evidence, testing, and data to establish root causes and verify corrective actions.
• Evaluate equipment, process parameters, tooling, setups, operator work methods, material handling, inspection methods, and operator-machine interactions to improve process performance and consistency. Apply practical experience with machine vision inspection systems, including lighting, optics, image acquisition, triggering/timing, inspection settings, and troubleshooting false accepts and false rejects; validate vision changes before implementation.
• Work with operators and Operations to develop and improve standardized work, operating instructions, and process controls that support consistent results across shifts.
• Design, execute, and analyze machine and process capability studies, controlled production trials, and Design of Experiments (DOE) where appropriate. Define test objectives, variables, measurement methods, sampling plans, and acceptance criteria; use results to establish operating limits and validate proposed changes.
• Lead corrective and preventive action teams and cross-functional PFMEA development and reviews. Maintain PFMEAs as processes and risks change, use findings to prioritize preventive actions and verify effectiveness, and keep PFMEAs, process flows, control plans, and work instructions aligned with production practices.
• Drive measurable, sustained improvements in safety, quality, scrap, variation, yield, and throughput using Process Control and Continuous Improvement methodologies. Provide technical leadership, coaching, and facilitation for the CI culture; identify barriers to improvement, recognize CI accomplishments, and use process data and operational metrics to prioritize opportunities and measure effectiveness.
• Coordinate with Engineering on new component process and equipment planning and support implementation of new products, materials, equipment, and processes into Operations.
• Oversee development and maintenance of heat treat procedures and practices.
• Lead a limited number of small and midsized operational projects, typically one or two midsized projects and three to six smaller projects per year. Projects may include specifying and selecting replacement equipment, coordinating installation, and validating performance; develop scope, estimates, financial proposals, and execution plans as appropriate.
• Follow Environmental,…