Senior Process Engineer (Gear & Spline)

CMI Group; Phoenix (AZ); On-site; USD 90,000 - 140,000; Full time

Benefits offered by this job

Competitive pay and benefits

Job summary

CMI Group is a precision aerospace machining company seeking a Senior Process Engineer to own and advance gear, spline, and shaping manufacturing processes. This role will develop, document, and continuously improve processes for complex gear components used in aerospace platforms — driving quality, throughput, and cost performance from raw material through final inspection.

Responsibilities include defining tooling and cutting parameters, creating CNC programs, and supporting NPI/FAI while

Qualifications

• Bachelor's degree in Mechanical, Manufacturing, or Industrial Engineering or equivalent hands-on experience.
• 5+ years of process engineering experience specifically in gear, spline, and shaping manufacturing.
• Working knowledge of gear geometry and inspection (involute profile, lead, pitch, runout) and familiarity with AGMA standards.
• Experience with CNC programming or process documentation in a machining environment.
• Understanding of GD&T and ability to read complex aerospace engineering drawings.
• Experience in an AS9100-certified manufacturing environment.
• Strong root-cause/corrective-action and process-capability (Cp/Cpk) skills.
• Direct experience with gear shapers, hobbing machines, or spline rolling equipment.

Responsibilities

• Develop and optimize manufacturing processes for gear shaping, spline rolling/shaping, hobbing, and related gear-form operations on aerospace hardware
• Create and maintain process documentation: routers, work instructions, setup sheets, and CNC programs in coordination with programming/manufacturing engineering
• Select and specify tooling, fixturing, and cutting parameters for gear shapers, hobbers, and CNC gear-generation equipment
• Troubleshoot process and quality issues on the shop floor (tooth form, lead, profile, runout, surface finish) and drive root-cause corrective action
• Support new part introduction (NPI) and first-article inspection (FAI/AS9102) for new gear and spline programs
• Partner with quality engineering on non-conformances, MRB dispositions, and continuous improvement of AGMA-rated tolerances
• Drive lean manufacturing and continuous improvement initiatives to reduce cycle time and scrap
• Collaborate with tooling suppliers, program management, and customer engineering on process capability and DFM feedback
• Support capital equipment justification and qualification for new gear-cutting and finishing technology

Skills

Gear & spline processes

CNC programming

Root-cause analysis

Lean manufacturing

GD&T

Education

Bachelor's degree in Mechanical, Manufacturing, or Industrial Engineering

Tools

Gear shapers

Hobbers

Spline rolling equipment

Job description

CMI Group is a precision aerospace machining company with five manufacturing locations across the greater Phoenix area and more than 250,000 square feet of world-class manufacturing space. For over 40 years, we've partnered with leading aerospace and defense OEMs on long-term contracts, machining critical components from exotic alloys and hard-to-manufacture materials. We're a family-oriented company where safety comes first and team members are invested in for the long haul.

About CMI Group

CMI Group is a precision aerospace machining company with five manufacturing locations across the greater Phoenix area and more than 250,000 square feet of world-class manufacturing space. For over 40 years, we've partnered with leading aerospace and defense OEMs on long-term contracts, machining critical components from exotic alloys and hard-to-manufacture materials. We're a family-oriented company where safety comes first and team members are invested in for the long haul.

Position Summary

CMI Group is seeking a Senior Process Engineer to own and advance our gear, spline, and shaping manufacturing processes. This role will develop, document, and continuously improve manufacturing processes for complex gear and spline components used in commercial, military, and business jet platforms — driving quality, throughput, and cost performance from raw material through final inspection.

What You'll Do

• Develop and optimize manufacturing processes for gear shaping, spline rolling/shaping, hobbing, and related gear-form operations on aerospace hardware
• Create and maintain process documentation: routers, work instructions, setup sheets, and CNC programs in coordination with programming/manufacturing engineering
• Select and specify tooling, fixturing, and cutting parameters for gear shapers, hobbers, and CNC gear-generation equipment
• Troubleshoot process and quality issues on the shop floor (tooth form, lead, profile, runout, surface finish) and drive root-cause corrective action
• Support new part introduction (NPI) and first-article inspection (FAI/AS9102) for new gear and spline programs
• Partner with quality engineering on non-conformances, MRB dispositions, and continuous improvement of AGMA-rated tolerances
• Drive lean manufacturing and continuous improvement initiatives to reduce cycle time and scrap
• Collaborate with tooling suppliers, program management, and customer engineering on process capability and DFM feedback
• Support capital equipment justification and qualification for new gear-cutting and finishing technology

What You'll Need

• Bachelor's degree in Mechanical, Manufacturing, or Industrial Engineering (or equivalent hands-on experience in lieu of degree).
• 5+ years of process engineering experience specifically in gear, spline, and shaping manufacturing (shaping, hobbing, grinding, or rolling) general machining process experience without direct gear/spline experience will not meet this requirement
• Working knowledge of gear geometry and inspection (involute profile, lead, pitch, runout) and familiarity with AGMA standards
• Experience with CNC programming or process documentation in a machining environment
• Understanding of GD&T and ability to read complex aerospace engineering drawings
• Experience in an AS9100-certified manufacturing environment
• Strong root-cause/corrective-action and process-capability (Cp/Cpk) skills
• Direct experience with gear shapers (Fellows, Lorenz, Mitsubishi, or similar), hobbing machines, or spline rolling equipment
• Comfortable working on the shop floor alongside machinists and quality inspectors, not just at a desk

Nice to Have

• Experience with CMM programming/inspection for gear features
• Background in exotic aerospace alloys (titanium, nickel-based superalloys, stainless)
• Six Sigma / Lean certification

Work Environment

• On-site role across CMI Group's Phoenix-area manufacturing facilities
• Regular time on the production floor in an active machine shop environment (PPE required)
• Standard business hours with occasional flexibility to support production schedules

Why CMI Group

• Work on mission-critical components for major aerospace and defense platforms, backed by decade-plus long-term contracts
• Family/relationship-oriented culture with an emphasis on building long-term careers, not just filling seats
• Investment in modern equipment & facilities with a growth environment
• Competitive pay and benefits, commensurate with experience