Senior Process Engineer

Pioneer Transformers; Waddell (AZ); On-site; USD 110,000 - 140,000; Full time

Job summary

ERMCO, expanding its manufacturing footprint in Arizona, seeks a Senior Process Engineer to drive operational excellence across our production floors, focusing on waste elimination, standardized work, safety, quality, and cost reduction.

You will lead Lean initiatives (Kaizen, VSM, 5S), develop and maintain WI/SOPs, analyze processes with SPC and Cp/Cpk, and collaborate with IT to implement digital manufacturing tools.

Qualifications

• Bachelor’s degree in Engineering (Mechanical, Industrial, Manufacturing, or related field) or equivalent experience.
• 7+ years of experience in a manufacturing or process engineering role.
• Lean methodology, Six Sigma certification preferred.

Responsibilities

• Lead Lean initiatives including Kaizen events, value stream mapping (VSM), 5S, and standard work development.
• Identify and eliminate waste across processes (overproduction, waiting, non-conforming material, etc.).
• Perform root cause analysis using 5 Whys, Fishbone, and A3 methodologies.
• Utilize SPC, Cp/Cpk analysis and data analytics to monitor and improve process performance.
• Develop and maintain WI and SOPs; design and optimize layouts to improve material flow and reduce lead time.
• Collaborate with IT to implement digital manufacturing tools (e.g., INFOR MES).
• Support CAPA and continuous quality improvement initiatives.
• Drive cultural and operational transformation across the organization.

Skills

Lean

Six Sigma

Data analysis

SPC

Process mapping

CAD

Education

Bachelor's degree in Engineering

Tools

CAD software

Process simulation tools

Job description

Senior Process Engineer

Overview

About ERMCO Electric Research and Manufacturing Cooperative, Inc. (ERMCO) was founded in 1964 by three electric cooperatives with a mission to deliver reliable transformers to rural communities often overlooked by larger manufacturers. Headquartered in Dyersburg, Tennessee, the company quickly established itself as an innovator—becoming the first U.S. plant exclusively designed to produce single-phase pad-mounted transformers.

Over the decades, ERMCO has expanded its capabilities and footprint through facility growth, strategic acquisitions, and continued investment in innovation. ERMCO designs and manufactures a comprehensive portfolio of liquid-filled distribution transformers, including single-phase and three-phase pad-mounted and pole-mounted transformers, supported by a full range of components such as amorphous and silicon steel transformer cores, fuses, bushings, disconnect switches, and circuit breakers.

Today, nearly 3,500 employees across eight sites in North America support the company’s role as a leader in powering energy grids to meet evolving customer demand. Now more than ever, ERMCO is positioned to be the industry’s Most Valued Partner. About ERMCO’s Arizona Facility

Electric Research and Manufacturing Cooperative, Inc. (ERMCO) is expanding into the Greater Phoenix market with a new 566,121-square-foot manufacturing facility in Waddell. The site will strengthen ERMCO’s Three-Phase transformer production and create new opportunities to advance automated manufacturing capabilities.

This marks ERMCO’s first expansion west of the Mississippi River. Operational readiness is underway, with the first transformer set to be manufactured in 2027.

ERMCO is offering long-term career opportunities across engineering, skilled trades, and operations. Team members at this facility will help build scalable processes, embed best practices, and drive alignment across the enterprise—playing a key role in shaping how work is done at ERMCO both locally and companywide.

Job Summary

The Senior Process Engineer plays a critical role in driving operational excellence and supporting the company’s lean transformation journey. This position is responsible for analyzing, improving, and standardizing manufacturing processes to enhance safety, quality, delivery, and cost (SQDC). The role will focus heavily on continuous improvement, waste elimination, and digitalization initiatives, including the development and implementation of standardized work instructions (WI).

Responsibilities

Key Responsibilities

• Lead and support Lean initiatives including Kaizen events, value stream mapping (VSM), 5S, and standard work development
• Identify and eliminate waste across processes (overproduction, waiting, non-conforming material, non value added motion, WIP inventory, etc.)
• Facilitate and be responsible for root cause analysis using tools such as 5 Whys, Fishbone, and A3 methodology
• Utilize Statistical Process Control (SPC), Cp/Cpk analysis, and other data-driven tools, data analytics to monitor and improve process performance.
• Analyze current manufacturing processes and implement improvements to increase efficiency, throughput, and quality
• Establish and maintain accurate labor standards and time studies to support capacity planning, costing, and continuous improvement initiatives
• Establish and monitor key performance indicators (KPIs) aligned with business objectives
• Champion a culture of continuous improvement and problem-solving at all levels of the organization to improve throughput and on-time deliver (OTD)
• Develop and maintain process flow diagrams and standard operating procedures (SOPs) and WI's (Work Instructions)
• Design and improve area and station layouts to optimize material flow and reduce lead time
• Collaborate with operations and IT teams to implement digital manufacturing tools (INFOR MES, digital WI platforms, etc.)
• Ensure work instructions are clear, standardized, and accessible at point-of-use
• Ensure processes meet quality standards and regulatory requirements
• Support corrective and preventive actions (CAPA) and continuous quality improvement initiatives
• Partner with Quality and Engineering teams to reduce defects and improve first-pass yield
• Act as a change agent to drive cultural and operational transformation

Qualifications

Minimum Qualifications

• Bachelor’s degree in Engineering (Mechanical, Industrial, Manufacturing, or related field) or equivalent experience.
• 7+ years of experience in a manufacturing or process engineering role.
• SME knowledge of Lean methodology, preferably with Six Sigma certification.
• Proficiency in data analysis and problem-solving techniques.
• Familiarity with process mapping, statistical process control (SPC, Cp-CpK, etc), and continuous improvement principles.
• Experience with CAD software and process simulation tools

Preferred Qualifications

• Experience in a previous Transformer company manufacturing environment.
• Knowledge of automation and control systems.
• Certification in Lean Six Sigma (Green Belt or higher)

Join ERMCO and TRANSFORM your career.

Job Locations

US-AZ-Waddell