Process Engineer
Listed on 2026-08-05
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Engineering
Manufacturing Engineer, Process Engineer, Quality Engineering, Mechanical Engineer
Process Engineer
The Process Engineer is responsible for developing, industrializing, and continuously improving advanced manufacturing and test processes for high-performance brushless DC motors and voice coil actuators used in aerospace & defense and other mission-critical applications. This role plays a critical part in new product development (NPD) by designing scalable, automated manufacturing solutions, driving cutting-edge process technologies, and ensuring full compliance with Advanced Product Quality Planning (APQP) requirements.
The Process Engineer partners cross-functionally with Design Engineering, Operations, Quality, and external suppliers to ensure successful product launches, robust process capability, and best-in-class cost, quality, and delivery performance.
General Responsibilities
- Key participant in the development of new production processes and/or adapt existing production processes for assembly, calibration and testing
- Define specifications for production equipment and interact with mechanization (in house) and/or equipment suppliers to ensure equipment will meet specifications
- Key participant in global new product development project teams to enable successful launch of new products
- Collaborate with other departments on process specifications, quality aspects, product specifications and continuity of equipment
- Influence product designs during new product development phase to ensure economical and defect free manufacture
- Developing new or improved manufacturing and testing processes that are necessary to achieve the performance and cost requirements of future device applications
- Organize the arranging of sample lines and process development equipment
- Key participant in advanced quality planning activities
- Coordinates all functional requirements, the reviewing of designs and debugging/qualifying new high volume assembly/test equipment or tooling
- Transferring knowledge to make site personnel
- Support improvement projects to reduce cycle time, defects and manufacturing costs
- Work with suppliers and contract manufacturers to ensure processes are capable, have sufficient controls in place, can meet out delivery requirements, and meet our cost targets
- Evaluate technical capabilities including tooling design, build experience, maintenance program, processes and process controls, cell automation- if required, quality control systems, and material knowledge
Experience / Qualifications
- A university degree required (i.e. Bachelors degree) or equivalent relevant work experience
- Must be a team player able to work in a fast-paced environment with demonstrated ability to handle multiple competing tasks and demands
- Strong communication skills; oral, written and presentation
- Strong organization, planning and time management skills to achieve results
- Strong personal and professional ethical values and integrity
- Holds self-accountable to achieving goals and standards
- Proficient in Microsoft Office programs (Outlook, Word, PowerPoint, and Excel)
- Strong interpersonal & collaboration skills to work effectively with all levels of the organization including suppliers and/or external customers
Drive innovation in motor manufacturing techniques (e.g., high-speed winding, precision balancing, coil insertion, magnetization, and VCA assembly processes).Support execution of APQP deliverables for new product programs, including:
- Process Flow Diagrams (PFD)
- PFMEA (Process Failure Mode & Effects Analysis)
- Control Plans
- Measurement System Analysis (MSA)
- PPAP readiness and submission support
- Electrical performance testing (torque, speed, efficiency)
- Thermal and environmental validation
- End-of-line functional testing with automated data capture
Serve as the process engineering lead on cross-functional NPD programs.
Provide DFM/DFA feedback to design engineering to optimize product manufacturability.
Drive manufacturing readiness from NBO through SOP and ramp-up, ensuring alignment with cost, quality, and delivery targets.
This position requires eligibility to obtain authorization under the International Traffic in Arms Regulations (ITAR) and/or the Export Administration Regulations (EAR). Non-US Persons, as defined in the ITAR and EAR, may not be eligible to obtain authorization.
Base Salary Range: $81,520.00 - $
At Sensata, our employees are the key to our success and growth. We recognize that each individual brings their own unique experience, therefore the base salary range information shown above is a general guideline only. Sensata considers several factors when extending an offer, including, but not limited to, a candidate's experience and qualifications, as well as internal equity,…
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