Senior Process Engineer

Copperweld; Fayetteville (NC); On-site; USD 110,000 - 140,000; Full time

Benefits offered by this job

Medical, dental, and vision plans

Paid time off

401(k) with company match

Life and disability insurance

Great Place to Work Certified

Job summary

Copperweld is seeking a Senior Process Engineer to lead complex process optimization across our manufacturing operations in Fayetteville. You will drive safety, reliability, and performance improvements, mentoring engineers and coordinating with production, quality, maintenance, EHS, and sales.

The role emphasizes Lean, Six Sigma, and Kaizen methods, with hands-on experience on process controls, automation, and data analysis. Travel to other Copperweld facilities may be required.

Qualifications

• Bachelor's degree in relevant engineering field.
• 7+ years of process engineering experience in manufacturing.
• Lean, Six Sigma, and Kaizen experience; Green/Black Belt preferred.

Responsibilities

• Lead Lean/Six Sigma process improvement projects to reduce scrap, downtime, and cost.
• Analyze and optimize production processes (wire drawing, cladding/bonding, annealing, stranding).
• Lead root-cause analysis on complex process and quality issues; implement lasting corrective actions.
• Develop process controls, monitoring systems, and KPIs.
• Manage capital projects from justification to startup, on time and on budget.
• Introduce new processes, products, and technologies into production.
• Collaborate with Production, Quality, Maintenance, EHS, and Sales to align with business needs.
• Mentor and train junior engineers and technicians.
• Ensure safety, environmental, and industry compliance.
• Apply outside best practices and new technologies.
• Perform other duties as assigned.

Skills

Lean

Six Sigma

Kaizen

Project management

Data analysis

PLCs

CAD software

Education

Bachelor's degree in Mechanical, Chemical, Industrial, Materials, Metallurgical, or Manufacturing Engineering

Master's degree preferred

Tools

Minitab

JMP

CAD software

PLC programming

Job description

If you are unable to complete this application due to a disability, contact this employer to ask for an accommodation or an alternative application process.

Senior Process Engineer

Full Time SG&A Fayetteville, TN, US

Join a high-performing team that is going for a home run!

Copperweld is looking for a driven, dedicated Senior Process Engineer to lead complex process optimization projects and improve operational efficiency across our manufacturing operations. This role is ideal for someone with advanced technical expertise in process engineering and a proven track record of driving continuous improvement in a manufacturing environment. The Senior Process Engineer will play a key role in ensuring the safety, scalability, reliability, and performance of our processes to meet both customer expectations and operational targets, while helping develop the next generation of engineers on our team.

• Lead process improvement projects using Lean, Six Sigma, and other structured methods to reduce scrap, downtime, and cost while improving quality and throughput.
• Analyze and optimize production processes such as [wire drawing, cladding/bonding, annealing, and stranding].
• Lead root cause analysis on complex process and quality issues, and put corrective actions in place that stick.
• Develop process controls, monitoring systems, and KPIs to track performance and sustain improvements.
• Manage capital projects, including automation and equipment upgrades, from justification and scoping through startup, on time and on budget.
• Lead the introduction of new processes, products, and technologies into production.
• Partner with Production, Quality, Maintenance, EHS, and Sales to align improvements with business and customer needs.
• Mentor and train junior engineers and technicians.
• Ensure processes meet safety, environmental, and industry requirements.
• Bring outside best practices and new technologies into our operations.
• Perform other duties as assigned.

WHAT you need to possess.

• Bachelor's degree in Mechanical, Chemical, Industrial, Materials, Metallurgical, or Manufacturing Engineering; Master's degree preferred.
• 7+ years of process engineering experience in a manufacturing environment, with a track record of measurable results.
• Hands-on experience with Lean, Six Sigma, and Kaizen; Green or Black Belt certification preferred.
• Experience with process control systems, automation (PLCs a plus), and statistical data analysis tools such as Minitab or JMP.
• Experience managing capital projects, including cost justification and vendor management.
• Ability to manage several projects at once and prioritize in a fast-paced plant setting.
• Clear communicator who works well with everyone from operators to senior leadership.
• Proficiency with Microsoft Office and CAD software; process simulation experience a plus.
• Wire and cable, metals, or continuous-process manufacturing experience preferred.
• Primarily plant-based, with regular time on the production floor around operating equipment, noise, and heat.
• Required PPE must be worn in production areas.
• Occasional travel to other Copperweld facilities as needed.
• Strong business outlook and room to grow
• Comprehensive medical, dental, and vision plans
• Paid time off and holidays
• 401(k) with company match
• Life and disability insurance
• Great Place to Work Certified!

Copperweld Bimetallic LLC is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity and/or expression, age, national origin, genetic information, disability, veteran status, or any other characteristic protected by federal, state or local law. Successful candidates will be required to pass drug screening and background checks.