Process Engineer

Charter Wire LLC; Milwaukee (WI); On-site; USD 75,000 - 110,000; Full time

Benefits offered by this job

Health benefits

Dental benefits

Vision benefits

401(k) with employer matching

Profit sharing

Life insurance

Disability coverage

PTO

Job summary

Charter Wire is seeking a Process Engineer to provide technical leadership on the floor, driving safety, quality, yield, and throughput improvements. You will analyze performance data, troubleshoot, and implement cross-functional solutions across shifts.

You will evaluate processes, develop standardized work, and lead DOE and PFMEA activities, collaborating with Engineering, Maintenance, and Quality to sustain gains.

Qualifications

• Bachelor’s Degree in Engineering or related field.
• 3+ years’ manufacturing process improvement experience.
• Knowledge of lean methods and problem-solving (Kaizen, 5S, 6σ).
• Knowledge of SPC, PFMEA, process control plans, and routings.

Responsibilities

• Observe processes on the floor and analyze data to identify losses.
• Evaluate equipment, tooling, setups to improve performance.
• Develop standardized work and process controls across shifts.
• Lead DOE studies and process capability analyses.
• Drive safety, quality, scrap reduction and throughput improvements.

Skills

Process engineering

Data analysis

Root cause analysis

Troubleshooting

Lean manufacturing

Kaizen / CI

Problem solving

Team collaboration

Effective communication

Education

Bachelor’s Degree in Engineering

Tools

SolidWorks

Pro-E

Machine vision systems

SPC

DOE

PFMEA

Job description

Charter Manufacturing is a fourth-generation family-owned business where our will to grow drives us to do it better. Join the team and become part of our family!

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, Quality and Safety Management System procedures and requirements, and meet the essential job requirements, with or without reasonable accommodation, as outlined in the job description

What you’ll need:

• Bachelor’s Degree in Engineering or related field
• Three plus years’ experience in a manufacturing environment improving processes
• Knowledge and experience with lean manufacturing methodologies and problem-solving techniques including Kaizen, 5S and 6σ
• Technical skills in manufacturing processes and methods including flow, layout, assembly, and production equipment
• Effective written and oral communication skills
• Self-starter with strong analytical skills
• Capacity to work in process improvement teams as a teacher, leader, and as a member
• Knowledge of Statistical Process Control (SPC), PFMEA, process control plans, process flow diagrams, and part routings
• Ability to handle multiple projects simultaneously
• Basic 2D/3D CAD software skills
• Proficient with the basis features of Microsoft Office products

Nice to haves:

• Five plus years' proven track record of leading safety, quality, and process improvement teams within a manufacturing environment
• Five plus years' experience in Heat Treat operations
• Certifications in Six Sigma Green Belt or above from a recognized lean source
• Demonstrated success in the application of lean/CI concepts in a manufacturing environment
• Experience with the Value stream approach a basis for Continuous Improvement
• Proven project management including Kaizen projects
• Experience with SolidWorks / Pro-E systems
• Proficiency with statistical and flow charting/process mapping software

About Charter Wire

Charter Wire is a leading Tier 1 supplier and manufacturer of Engineered Shaped Wire, Cold Finished Bar, and Cold-Headed and Stamped Components to various industries, including Automotive, Agriculture, Construction, Consumer, Industrial and Oil & Gas. Charter Wire is a member of the Charter Manufacturingfamily of companies.

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We offer comprehensive health, dental, and vision benefits, along with a 401(k) plan that includes employer matching and profit sharing. Additionally, we offer company-paid life insurance, disability coverage, and paid time off (PTO).