Process Engineer

HSM (Hickory Springs Manufacturing) Company; Hickory (NC); On-site; USD 90,000 - 120,000; Full time

Benefits offered by this job

Health insurance

401(k) plan

Paid time off

On-site medical clinics

Teladoc access

Professional development assistance

Discounts with partners

Job summary

Hickory Springs Manufacturing (HSM) seeks a seasoned Process Engineer to design and optimize metal fabrication and assembly processes across high-volume operations. You will lead NPI projects, define process layouts, tooling, and welding equipment to drive efficiency and quality.

This role emphasizes Lean manufacturing, Six Sigma, PFMEA, and control plans, with responsibilities in equipment commissioning, line stability, and continuous improvement.

Qualifications

• Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, or related field.
• 4+ years of experience in process engineering and manufacturing environments.
• Experience with welding (MIG, TIG, robotic) and fixture design.
• Experience with NPI, tooling, line layouts, and process documentation.
• Knowledge of Lean, Six Sigma, PFMEA, SPC and control plans.

Responsibilities

• Develop and optimize manufacturing processes for metal fabrication and assembly.
• Lead process development from design through production launch (NPI).
• Create process flow diagrams, line layouts, and standard work instructions.
• Define tooling, fixtures, and welding equipment; support equipment installation and validation.
• Improve assembly line efficiency, takt time, and workflow; support pilot builds and production readiness.
• Drive Lean manufacturing, Six Sigma, and VAVE initiatives; improve cycle time and material flow.
• Ensure compliance with ISO 9001, IATF 16949, and VDA 6.3; support PFMEA, control plans, and process validation.

Skills

Process engineering

Manufacturing engineering

Metal fabrication

Assembly environments

Welding processes (MIG TIG robotic)

Tooling and fixture design

Production line layout

NPI / equipment commissioning

Lean manufacturing

Six Sigma

PFMEA

Control plans

Education

Bachelor's degree in Mechanical Engineering (or related)

Manufacturing/Industrial Engineering

Tools

Welding equipment

Process validation

Job description

Hickory Metal Plant
Hickory, NC 28602, USA

Founded in 1944, HSM is athird generation, privately held company with a rich history of innovation and a commitment to our people. With 25 locations across the U.S. and corporate headquarters in Hickory, NC and Huntersville, NC, we specialize in manufacturing components for furniture, bedding, transportation, packaging, automotive, and healthcare industries. Our expertise also includes designing and building automated production machinery. HSM products from sofa springs to swimming pool noodles and bus seats, touch everyday life in countless ways.

At HSM, our success is built on our people. We foster a culture of teamwork, innovation, and shared success. If you're looking for a meaningful place to grow and make an impact, we want to hear from you!

What You Will Do

• Process Engineering & Manufacturing Support
  
  • Develop and optimize manufacturing processes for metal fabrication and assembly
  • Support cutting, forming, welding, and finishing operations
  • Troubleshoot production issues related to weld quality, fit-up, and dimensional variation
  • Improve scrap reduction, yield, and throughput
• New Product Launch (NPI) / Industrialization
  
  • Lead process development from design through production launch
  • Create process flow diagrams, line layouts, and standard work instructions
  • Define tooling, fixtures, and welding equipment
  • Support equipment installation, commissioning, and validation
• Assembly Process Optimization
  
  • Improve assembly line efficiency, takt time, and workflow
  • Support mechanical assembly, fastening, and product integration
  • Assist with pilot builds, run-at-rate, and production readiness
• Continuous Improvement / Lean Manufacturing
  
  • Drive Lean manufacturing, Six Sigma, and VAVE initiatives
  • Improve cycle time, labor efficiency, ergonomics, and material flow
  • Use root cause analysis and data-driven problem solving
• Quality & Compliance
  
  • Ensure compliance with ISO 9001, IATF 16949, and VDA 6.3
  • Support PFMEA, control plans, and process validation
  • Partner with Quality to improve process capability and defect prevention

Travel requirements ~ 20%

What You Bring

Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, or related field

4+ years of experience in:

Process engineering

Manufacturing engineering

Metal fabrication or assembly environments

Experience with:

Welding processes (MIG, TIG, robotic welding preferred)

Tooling and fixture design

Production line layout and process design

Experience in automotive, transportation, or high-volume manufacturing

Knowledge of:

Lean manufacturing / Six Sigma

PFMEA, control plans, SPC

Experience with new product introduction (NPI) and equipment commissioning

Why Join Us

• Health & Wellness: Affordable medical, dental, and vision insurance plans, including an innovative global healthcare option for qualified participants.
• Retire:401(k) with company match, fully vested from day one.
• Paid Time Off: Competitive PTO: 3 Weeks of Vacation + 9 company paid holidays.
• On-Site Medical Clinics: Free for you and covered dependents.
• Teladoc: 24/7 access with no copay.
• Professional Development: Tuition reimbursement, professional development assistance and career growth opportunities.
• Discounts: Enjoy discounts with HSM partners, including Dollywood Parks & Resort, Verizon Wireless, and more.

EEOC

At HSM, we believe that our diversity creates a productive workplace. All qualified candidates will receive consideration for employment without regard to age, race, creed, color, religion, sex, national origin, ancestry, marital status, affectionate or sexual orientation, gender identity or expression, or protected veteran status and will not be discriminated against on the basis of disability.

Equal Opportunity Employer/Protected Veterans/Individuals with Disabilities
This employer is required to notify all applicants of their rights pursuant to federal employment laws.For further information, please review the Know Your Rights notice from the Department of Labor.