Process Engineer

Position Overview: We are seeking a hands-on and detail-oriented Process Engineer to join our dynamic manufacturing operations team. This role is critical in supporting yield improvement, day-to-day production troubleshooting, and new product introduction (NPI) within a fast-paced 24/7 high-volume production environment. You will work directly on 1st shift (8:30AM – 5PM) to ensure optimal performance of processes, effective support to production teams, and smooth onboarding of new products.This position is an excellent opportunity for engineers looking to make a significant impact in advanced manufacturing operations, supporting blue-chip customers with world-class standards for quality and delivery.The Process Engineer will be expected to work on-site five days a week in our Somerset, NJ office.Key Responsibilities:Provide real-time process support for production teams on the afternoon shift, ensuring minimal downtime and swift issue resolution.Analyze and improve manufacturing yields, identifying root causes of scrap, rework, and process variation through data-driven methods (e.g., SPC, FMEA, 5 Whys, Fishbone).Lead or support new product introduction (NPI) activities, including process validation, work instruction development, and ramp-up readiness.Collaborate with cross-functional teams (Quality, Maintenance, Operations) to drive continuous improvement initiatives focused on cost, efficiency, and throughput.Develop and maintain standard operating procedures, process documentation, and training materials for manufacturing staff.Support implementation of Lean manufacturing and Six Sigma techniques to reduce waste and improve process control.Monitor key performance indicators (KPIs) for yield, cycle time, downtime, and quality, with regular reporting and action planning.Participate in audits, customer visits, and internal reviews as a technical subject matter expert for assigned process areas.Ensure compliance with safety, quality, and regulatory standards applicable to manufacturing operationsOther Important Responsibilities:Consistently demonstrate the ability to prioritize tasks to ensure most critical processes impacting business results are being addressed.Thorough documentation of existing processes and new process development, inclusive of progressive results, specific equipment parameters and work instructions where appropriate.Other miscellaneous duties as assigned.Qualifications:Bachelor's degree in Manufacturing, Mechanical, Industrial, or Chemical Engineering (or equivalent field).A minimum of 5 years (or more) of experience in a high-volume manufacturing environment (preferably supporting 24/7 operations).Proven experience in yield improvement, root cause analysis, and process troubleshooting.Familiarity with NPI processes, including process validation and production readiness.Strong working knowledge of Lean, Six Sigma, SPC, and other process control methodologies.Proficiency with data analysis tools (Excel, Minitab, JMP, etc.) and manufacturing systems (MES, ERP).Excellent communication and collaboration skills across shifts and cross-functional teams.Willingness to work on the weekends or afternoon shift (3 PM – 11 PM) and occasionally support coverage across other shifts as needed.Experience in regulated manufacturing (e.g., automotive, aerospace, electronics, or medical device).Six Sigma Green Belt or Lean certification.Hands-on experience with automation systems, sensors, or high-throughput equipment.Physical requirements and work environment:Must be able to lift 20 lbs;Must be able to sustain office work for 8+ hours per day including the following:Sitting in an office chairTypingReaching for the telephoneStanding at office equipmentHearing for phone useSight for computer useMust be able to sustain factory work as needed including the following:Standing at machineryReaching and pulling to operate machinerySight for machinery operationWalking through shopOffice environment is of moderate noise level.Shop noise levels are such that protective ear-coverings are recommended.