Manufacturing Process Engineer - Lean & Capital Projects

Sterling St James LLC; Decorah (IA); On-site; USD 75,000 - 95,000; Full time

Job summary

Sterling St James LLC in Decorah, Iowa is seeking a Manufacturing/Process Engineer to develop, maintain, and improve production processes. You will focus on process stability, continuous improvement, and capital project support in collaboration with Operations, Quality, Maintenance, and Supply Chain.

The role requires a Bachelor’s degree in Engineering and 4–7 years hands-on experience in manufacturing, with strong knowledge of Lean, Six Sigma, and process documentation.

Qualifications

• Bachelor’s degree in Engineering (Manufacturing, Industrial, Mechanical) required.
• 4–7 years of hands-on manufacturing or process engineering experience in a production environment.
• Experience with lean manufacturing.
• Experience with capital projects.
• Strong working knowledge of process capability, cycle time analysis, scrap reduction, and efficiency metrics.
• Proven experience developing and maintaining detailed work instructions, standard work, and process documentation.
• Experience supporting capital equipment installation, commissioning, and process validation activities.
• Hands-on with production teams.
• Advanced problem-solving skills with practical application of root cause analysis methodologies.
• Ability to travel up to 15%.

Responsibilities

• Support daily manufacturing operations by monitoring process performance.
• Develop, document, and maintain work instructions, process flows, routings, and standard work.
• Analyze production data (scrap, rework, cycle time, downtime) to identify process improvement opportunities.
• Implement process changes to improve safety, quality, efficiency, and throughput.
• Support new product or process introductions by assisting with process setup, trials, and documentation.
• Drive and actively participate in continuous improvement initiatives by applying Lean, Six Sigma, and related methodologies.
• Lead root cause analysis efforts and implement corrective and preventive actions to address process issues.
• Proactively identify and eliminate waste, reduce scrap, minimize labor inefficiencies, and lower material costs.
• Champion kaizen events and consistently monitor improvement metrics and results.
• Sustain process improvements by updating documentation and conducting operator training sessions.
• Lead capital project initiatives by overseeing all phases, including equipment selection, justification, installation, and startup, to enhance operational capabilities and support business objectives.
• Develop and support capital requests by preparing ROI analyses and technical specifications that align with organizational goals and cost reduction strategies.
• Coordinate cross-functional collaboration with vendors, Maintenance, and Operations teams to ensure seamless equipment installation and successful commissioning.
• Support process validation, capability studies, and acceptance testing for new or modified equipment to ensure compliance with quality, safety, and performance standards.
• Maintain and update documentation, standard work, and process instructions to reflect changes following capital project implementation, ensuring sustained improvements and knowledge transfer.
• Proactively support manufacturing processes by ensuring alignment with internal quality systems and customer requirements, driving continuous improvement and operational excellence.
• Take initiative in assisting with non-conformance investigations and implementing corrective actions to maintain high standards of product quality and compliance.
• Integrate safety, ergonomics, and risk mitigation strategies into process design and improvement efforts, fostering a safe and efficient work environment.
• Actively support internal audits and documentation reviews, contributing to sustained compliance and process reliability.
• Champion a culture of quality, safety, and continuous improvement throughout the shop floor to consistently achieve business objectives.

Skills

Lean

Six Sigma

Root Cause Analysis

Continuous Improvement

Problem Solving

Cross-functional Collaboration

Team Leadership

Communication Skills

Hands-on Manufacturing

Process Documentation

Education

Bachelor’s degree in Engineering (Manufacturing/Industrial/Mechanical)

Job description

Sterling St James LLC in Decorah, Iowa is seeking a Manufacturing/Process Engineer to develop, maintain, and improve production processes. You will focus on process stability, continuous improvement, and capital project support in collaboration with Operations, Quality, Maintenance, and Supply Chain.

The role requires a Bachelor’s degree in Engineering and 4–7 years hands-on experience in manufacturing, with strong knowledge of Lean, Six Sigma, and process documentation.