Senior Process Engineer

Actalent; Elmhurst (IL); On-site; USD 100,000 - 130,000; Full time

Job summary

Actalent is seeking a Sr. Process Engineer in Elmhurst, IL to lead the Process Engineering function and guide day-to-day manufacturing engineering activities.

You will oversee process development, CNC programming, tooling specs, gear metrology analysis, and continuous improvement while mentoring the engineering team. The ideal candidate brings hands-on gear manufacturing experience, strong leadership, and a track record in process development, CNC programming, gear inspection, and team

Qualifications

• Must have 2+ years in a production-based engineering role.
• Experience in machining, metals, or automotive environments.
• Gear manufacturing background is highly preferred.

Responsibilities

• Lead, mentor, and support a team of Process Engineers.
• Review and approve process plans, routings, tooling packages, and docs.
• Develop and optimize manufacturing processes for precision gear production.
• Create CNC programs and tooling specs for gear operations.
• Analyze gear metrology results and drive improvements.
• Coordinate with Production, Quality, and Supply Chain to resolve issues.
• Support quoting activities for new and existing business.

Skills

Process engineering

Manufacturing process

CNC programs

GDT

Heat treat

Root cause failure analysis

Process improvement

SPC

PFMEA

Control plans

ISO 9001

Quoting

Leadership

Supervisory skills

Lean manufacturing

Six Sigma

Capital equipment

Tooling design

Project management

Machining process

Cost reduction

SolidWorks

ERP system

Job description

Description

Position Overview: The Sr. Process Engineer will lead the Process Engineering function while remaining heavily involved in day-to-day manufacturing engineering activities. This person will oversee process development, CNC programming, tooling specifications, gear metrology analysis, quoting support, continuous improvement initiatives, and engineering documentation. They will also provide leadership and guidance to the engineering team.

Key Responsibilities

• Lead, mentor, and support a team of Process Engineers.
• Review and approve process plans, routings, tooling packages, and technical documentation.
• Develop and optimize manufacturing processes for precision gear production.
• Create CNC programs and tooling specifications for gear hobbing, shaping, and grinding operations.
• Analyze gear metrology results and drive corrective actions and process improvements.
• Coordinate with Production, Quality, and Supply Chain to resolve manufacturing issues.
• Support quoting activities for new and existing business opportunities.
• Maintain PFMEAs, Control Plans, work instructions, and SPC documentation.
• Ensure compliance with AGMA, ISO 9001, AS9100, and customer-specific requirements.
• Lead continuous improvement initiatives focused on throughput, scrap reduction, tooling life, and overall manufacturing efficiency.
• Support capital equipment selection, installation, and validation projects.

Previous Quoting Experience Is Preferred.

Must be able to meet ITAR requirements.

Additional Intake Notes

• Reports to: Mete (Quality & Engineering Manager)
• Will be the lead engineer and primary technical resource for the engineering team.
• Position opened due to the retirement of a former Quality & Engineering leader.
• Direct Placement preferred (open to CTH if necessary).
• Salary target: $100,000 - $130,000
• Schedule: Monday-Friday, First Shift, 7:00 AM - 3:30 PM
• No travel required.
• Personal history check required.
• Panel 5 drug screen required.
• Must be authorized to work in the U.S.
• Hiring process consists of an in-person interview with the hiring manager, followed by an introduction to the CEO.
• Client would like to move quickly and fill the position ASAP.

Ideal Candidate

We're looking for someone who combines hands-on gear manufacturing expertise with leadership capabilities. Candidates coming from precision machining, gearing, aerospace, defense, heavy industrial, or highly regulated manufacturing environments should be strong fits, particularly if they've had responsibility for process development, CNC programming, gear inspection, and engineering team leadership.

Skills

• Process engineering
• Manufacturing process
• itar
• cnc programs
• gd&t
• heat treat
• root cause failure analysis
• process improvement
• spc
• pfmea
• control plans
• iso 9001
• quoting
• leadership communication
• supervisory skills
• lean manufacturing
• six sigma
• capital equipment
• tooling design
• project management
• machining process
• cost reduction
• solidworks
• erp system

Top Skills Details

• Process engineering
• Manufacturing process
• itar
• cnc programs
• gd&t
• heat treat
• root cause failure analysis
• process improvement
• spc
• pfmea
• control plans
• iso 9001

Additional Skills & Qualifications

• Prepare gear designs for production.
• Prepare quotes on new and existing business.
• Evaluate and improve on processes in manufacturing systems.
• Maintain reliable and safe manufacturing systems while improving production rates, efficiencies, yields, costs and changeovers.
• Improve process capability and production volume while maintaining and improving quality standards.
• Develop and implement systems that optimize all phases of production process.
• Provide suggestions during incident investigations.
• Advise on corrective actions.
• Work with equipment designers and manufacturing officers to develop a cost-effective and working production process.
• Ensure projects are completed on time.
• Ensure financial budgets are followed.
• Research and purchase new manufacturing technology.

MUST HAVE

• 2 years in a production based engineering role
• machining, metals or automotive experience
• GEAR manufacturer would be perfect

Experience Level

Intermediate Level

Job Type & Location

This is a Permanent position based out of Elmhurst, IL.

Pay And Benefits

• The pay range for this position is $100000.00 - $130000.00/yr.
• Individual compensation offered for this position within this range will depend on many factors, including qualifications, skills, relevant experience, job knowledge, geographic location, internal equity, and other pertinent job-related factors.
• Not specified in the job description. Additional information to be gathered during follow-up discussions with the hiring team.

Application Deadline

This position is anticipated to close on Nov 6, 2026.

Workplace Type

This is a fully onsite position in Elmhurst,IL.

About Actalent

Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 20,000 consultants and 5,000 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500. We are proud to be an Engineering News-Record (ENR) Top 500 Design Firm for our engineering design services and a ClearlyRated Best of Staffing® winner for both client and talent service.

The company is an equal opportunity employer and will consider all applications without regard to race, sex, age, color, religion, national origin, veteran status, disability, sexual orientation, gender identity, genetic information or any characteristic protected by law.

San Francisco Fair Chance Ordinance

Pursuant to the San Francisco Fair Chance Ordinance, for all positions located in the city and county of San Francisco, we will consider for employment qualified applicants with arrest and conviction records.

Massachusetts Lie Detector

It is unlawful in Massachusetts to require or administer a lie detector test as a condition of employment or continued employment. An employer who violates this law shall be subject to criminal penalties and civil liability.

Use of Artificial Intelligence (AI)

We may use Artificial Intelligence (AI) to support parts of our hiring process, including sourcing, screening, and evaluating candidates. AI helps assess applications and qualifications, but final decisions are made by our hiring team. By applying, you acknowledge and agree that your application may be reviewed using AI tools.