Senior Process Engineering Leader — Multi-Site Automation

HSM (Hickory Springs Manufacturing) Company; Huntersville (NC); On-site; USD 110,000 - 170,000; Full time

Benefits offered by this job

Health & wellness benefits

401(k) with company match

PTO 3 weeks + 9 holidays

On-site medical clinics

Teladoc access

Tuition reimbursement

Employee discounts with partners

Job summary

HSM (Hickory Springs Manufacturing) Company seeks a senior Process Engineering leader to drive manufacturing excellence across multiple sites in the United States. You will provide technical leadership to process and manufacturing engineering teams, establish standard methods, and raise performance across metal fabrication, welding, foam, cut-and-sew, and assembly.

The role requires eight years of progressive manufacturing or process engineering, plus five years of leadership across facilities;

Qualifications

• Bachelor’s degree in Mechanical/Manufacturing/Industrial Engineering or related technical discipline; master’s degree preferred.
• Eight years of progressive manufacturing or process engineering experience.
• Five years of engineering leadership experience across multiple facilities.
• Experience in automotive, commercial transportation, specialty vehicle, or Tier 1/2 manufacturing preferred.
• Broad manufacturing-process expertise including metal fabrication, MIG/laser welding, foam, cut-and-sew, and mechanical assembly.
• Working knowledge of tooling, fixtures, process validation, line balancing, capacity planning, material flow, and ergonomics.
• Experience with PLC-controlled equipment, robotics, automation systems, Industry 4.0 initiatives.
• Strong knowledge of ISO 9001; IATF 16949, VDA 6.3, and automotive customer-specific requirements preferred.
• Experience with APQP, PPAP, PFMEA, control plans, process flow diagrams, MSA, SPC, Run-at-Rate, and pre-launch activities.
• Strong communication, presentation, project-management, and stakeholder-influence skills.
• Proven ability to develop engineering talent and build high-performing teams.

Responsibilities

• Lead process engineering across multiple sites and provide technical leadership to engineering teams.
• Establish consistent engineering methods, documentation, performance metrics, and best practices.
• Strengthen process capability and manufacturing performance across the division.
• Mentor engineering professionals and build a strong technical organization.
• Develop, validate, optimize, and standardize processes across metal fabrication, welding, foam, cut-and-sew, and final assembly operations.
• Improve safety, quality, throughput, labor utilization, equipment performance, and overall manufacturing efficiency.
• Lead structured root-cause investigations using data-driven analysis and decision-making.
• Advance line balancing, capacity planning, workstation design, material flow, tooling, fixtures, and ergonomics.
• Drive reductions in scrap, cycle time, waste, and manufacturing cost.
• Guide manufacturing-readiness activities from concept through start of production.
• Lead APQP deliverables and collaborate with Product Development to improve design for manufacturability and scalability.

Skills

Lean Manufacturing

Six Sigma

Kaizen

Statistical analysis (SPC/DOE)

Project management

Leadership across facilities

Education

Bachelor’s degree in Mechanical/Manufacturing/Industrial Engineering

Master’s degree preferred

Tools

APQP/PPAP

PFMEA

Control plans

MBD/DOE Excel data analysis

PLC-controlled equipment & robotics

Job description

HSM (Hickory Springs Manufacturing) Company seeks a senior Process Engineering leader to drive manufacturing excellence across multiple sites in the United States. You will provide technical leadership to process and manufacturing engineering teams, establish standard methods, and raise performance across metal fabrication, welding, foam, cut-and-sew, and assembly.

The role requires eight years of progressive manufacturing or process engineering, plus five years of leadership across facilities;