Process Engineer - Machining, Maintenance, Refractory

Charter Automotive; 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 (P)?

Life insurance

Job summary

Charter Manufacturing in Woodstock, IL is hiring a Process Engineer to drive continuous improvement across maintenance, refractory, and machining operations at our Woodstock facility. You will lead projects that improve safety, quality, productivity, and cost efficiency, collaborating with cross-functional teams to turn engineering ideas into practical manufacturing solutions.

Ideal candidates have a Bachelor's degree in Engineering and 3+ years of process-improvement experience, plus Lean, Six

Qualifications

• Requires a Bachelor's degree in Engineering or related field.
• 3+ years of process-improvement experience in manufacturing.
• Experience with Lean Manufacturing and problem-solving methodologies (Kaizen, 5S, Six Sigma).
• Knowledge of manufacturing processes, equipment, layout, and assembly methods.
• Working knowledge of SPC, PFMEA, process control plans, and process flow diagrams.
• Strong analytical, communication, and cross-functional collaboration skills.
• Proficiency with CAD software (SolidWorks, Pro/E).

Responsibilities

• Drive process improvements across maintenance, refractory, and machining operations to enhance safety, quality, yield, throughput, and efficiency.
• Lead CI initiatives using Lean, Six Sigma, and structured problem-solving to reduce waste and variation.
• Troubleshoot manufacturing issues by analyzing data, identifying root causes, and implementing corrective actions.
• Manage engineering and capital projects from investigations to startup, coordinating with internal teams and contractors.
• Support new equipment/process development with Engineering and Operations to introduce new methods and materials.
• Develop process standards, SOPs, work instructions, CP plans, and KPIs to drive consistency.
• Coach cross-functional teams to foster a culture of continuous improvement.

Skills

Lean Manufacturing

Problem-solving

Kaizen

5S

Six Sigma

SPC

PFMEA

Cross-functional collaboration

Education

Bachelor's degree in Engineering

Tools

SolidWorks

Pro/ENGINEER (Pro/E)

2D/3D CAD

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! Alternative job title: Manufacturing Engineer 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.

Location and Schedule

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.

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).

OUR STORY

Charter Manufacturing is a family‑owned group of diversified metals manufacturing businesses founded in 1936 and headquartered in Mequon, Wis. Our will to grow drives our success. It is fueled by a team of respected and dedicated employees committed to continuous improvement and an entrepreneurial spirit that thrives within the Charter family.

WE ARE INVESTED IN YOU

When you work at Charter Manufacturing you’re part of a four‑generation family business. That means, you’re not just an employee, you’re one of our family members. We believe in mutual trust. Employees are respected and empowered to explore new and better ways to impact the success of the company. Employees, at every level, are valued for their motivation to deliver the best products and service. We are in this together. Charter has a thriving team environment. Part of being a family means we collaborate, learn, thrive and benefit – together. We are committed to your future. The forward thinking and enthusiasm from our team drives us to create resources and opportunities for employees to learn, develop and create their own future. We celebrate you. We are successful because of our employees — and their great work doesn’t go unnoticed. We recognize and reward our employees for their contributions. Visit our website to learn more about our family of companies. View our 2022 Sustainability Report. To review our data use practices, visit our Company Privacy Policy. View/Download Employment-related Notices: FMLA Poster E‑Verify Participation Poster (English & Español) Right to Work Poster (English & Español)

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