Process Engineer - Machining, Maintenance, Refractory

Charter Manufacturing Company; Woodstock (IL); On-site; USD 82,000 - 103,000; Full time

Benefits offered by this job

Health, dental and vision benefits

401(k) with employer matching and plan

Life insurance

Disability coverage

Paid time off

Job summary

Charter Casting, based in Woodstock, IL, is seeking a Process Engineer to drive continuous improvement across machining, maintenance, and refractory operations. You will lead cross-functional projects to improve safety, quality, yield, throughput, and cost efficiency on a high-part-volume shop floor.

Responsibilities include leading Lean/Six Sigma initiatives, developing process standards, troubleshooting production issues, and managing capital projects from estimate to start-up.

Qualifications

• Bachelor’s degree in Engineering or related field.
• 3+ years of experience improving processes in manufacturing.
• Experience with Lean Manufacturing and problem-solving methodologies (Kaizen, 5S, Six Sigma).
• Knowledge of manufacturing processes, equipment, workflow, plant layout, and assembly methods.
• Working knowledge of SPC, PFMEA, process control plans, process flow diagrams, and part routings.
• Strong analytical, troubleshooting, communication, and cross-functional collaboration skills.
• Basic proficiency with 2D/3D CAD software.

Responsibilities

• Drive process improvements across maintenance, refractory, and machining operations to enhance safety, quality, yield, throughput, and efficiency.
• Lead continuous improvement initiatives using Lean, Six Sigma, and structured problem solving to reduce variation and waste.
• Troubleshoot manufacturing challenges by partnering with production teams, analyze data, identify root causes, implement corrective actions.
• Manage engineering and capital projects from investigation to startup, coordinating with internal teams and contractors.
• Support new equipment and process development with Engineering and Operations.
• Develop process standards, SOPs, work instructions, control plans, and KPIs to drive consistency.

Skills

Lean Manufacturing

Six Sigma

Kaizen

5S

Problem solving

Education

Bachelor’s degree in Engineering

Tools

SolidWorks

Pro/E (Pro/ENGINEER)

CAD software

Statistical analysis software

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 Casting is hiring a Process Engineer for Machining, Maintenance, and Refractory!

Make an impact where engineering meets hands-on manufacturing!

Charter Casting is seeking a Process Engineer to drive continuous improvement across maintenance, refractory, and machining operations at our Woodstock, IL facility. In this role, you’ll tackle meaningful engineering challenges, optimize manufacturing processes, and lead projects that improve safety, quality, productivity, and cost competitiveness. You’ll collaborate with cross-functional teams to turn innovative ideas into practical solutions while helping shape the future of our manufacturing operations.

Position specifics:

• Location: Woodstock, IL
• Schedule: Onsite
• Travel: Up to 10% to other Charter locations or vendors
• Work Authorization: Applicants must be authorized to work for any employer in the U.S. Charter Manufacturing is unable to sponsor employment visas at this time.

Key responsibilities:

• Drive process improvements across maintenance, refractory, and machining operations to enhance safety, product quality, manufacturing yield, throughput, and operational efficiency.
• Lead continuous improvement initiatives using Lean Manufacturing, Six Sigma, and structured problem-solving techniques to reduce process variation, eliminate waste, and improve performance.
• Troubleshoot manufacturing challenges by partnering directly with production teams, analyzing process data, identifying root causes, and implementing sustainable corrective and preventive actions.
• Manage engineering and capital projects from investigation and cost estimation through financial justification, equipment installation, implementation, and startup, collaborating with internal teams and external contractors.
• Support new equipment and process development by partnering with Engineering and Operations to introduce new components, materials, technologies, and manufacturing methods.
• Develop process standards and performance metrics , including standard operating procedures, work instructions, process control plans, and operational KPIs to drive consistency and measurable results.
• Champion a culture of continuous improvement by coaching and collaborating with cross-functional teams, removing barriers to progress, and recognizing achievements that strengthen operational performance.

What you’ll need:

• Bachelor’s degree in Engineering or a related field.
• 3+ years of experience improving processes in a manufacturing environment.
• Experience with Lean Manufacturing and problem-solving methodologies, including Kaizen, 5S, and Six Sigma.
• Knowledge of manufacturing processes, production equipment, workflow, plant layout, and assembly methods.
• Working knowledge of Statistical Process Control (SPC), PFMEA, process control plans, process flow diagrams, and part routings.
• Strong analytical, troubleshooting, communication, and cross-functional collaboration skills, with the ability to lead or participate in multiple improvement projects.
• Basic proficiency with 2D/3D CAD software.

Nice to have:

• 5+ years of experience leading safety, quality, and process improvement initiatives in manufacturing.
• Experience with CNC programming and machining processes.
• Six Sigma Green Belt certification or higher from a recognized organization.
• Demonstrated success applying Lean Manufacturing, continuous improvement, and value stream methodologies.
• Proven project management experience, including leading Kaizen events or improvement projects.
• Experience with SolidWorks or Pro/ENGINEER (Pro/E).
• Proficiency with statistical analysis, flowcharting, and process mapping software.

Ready to put your engineering expertise to work and make a measurable impact?

Join a team where collaboration, innovation, and continuous improvement drive success. Take the next step in your career with Charter Casting—apply today!

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The annual hiring range for this position is: $82,000-$102,500. The actual base pay offered to the successful candidate will depend on various factors, including but not limited to job-related skills, experience, and qualifications. Compensation decisions are tailored to the unique circumstances of each position and candidate.

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).