Sr. Manufacturing Process Engineer

Barnes Group; Warren (MI); On-site; USD 110,000 - 140,000; Full time

Job summary

Barnes Group seeks an experienced Manufacturing/Process Engineer to lead the planning, development, and optimization of aerospace machining and related processes. You will ensure conformance to AS9100/Nadcap and coordinate with Quality, Operations, and customers to deliver reliable production readiness.

The role includes mentoring engineers, supporting production during transitions, and driving continuous improvement across safety, quality, and efficiency initiatives.

Qualifications

• Bachelor's degree in Manufacturing, Mechanical, Industrial, Aerospace Engineering or equivalent.
• 10+ years of progressive manufacturing/process engineering experience in a complex machining environment.

Responsibilities

• Independently plan, develop, implement, validate, and continuously improve manufacturing processes for aerospace components.
• Provide decisive shop-floor engineering support for production interruptions and setup issues.
• Develop CNC machining strategies, tooling, workholding, and fixtures for multi-axis operations.
• Interpret drawings and ASME Y14.5 GD&T to establish functional datum strategies and manufacturable process plans.
• Troubleshoot CMM and metrology results; coordinate with Quality to establish measurement methods.
• Create and maintain manufacturing plans, operation sheets, routings, BOMs, and controlled documentation in ERP.
• Lead technical investigations, root-cause analysis, and corrective actions for nonconformances.
• Coordinate requirements with Quality, Operations, Program Management, and outside processors to meet AS9100 and Nadcap standards.
• Manage multiple projects, set milestones, and report risk to management.
• Support quotations and make/buy decisions through manufacturability reviews and cost inputs.
• Develop process qualifications, first-article support, and production readiness activities.

Skills

Project leadership

Problem solving

Communication

Mentoring

Education

Bachelor's degree in Engineering

Tools

CAD/CAM

Siemens NX

ERP systems

Job description

Essential Responsibilities:

• Independently plan, develop, implement, validate, and continuously improve manufacturing processes for complex aerospace components, including machining, welding, heat treatment, EDM, plasma spray, NDT, and other special processes.
• Provide decisive, responsive shop-floor engineering support for production interruptions, setup issues, machining instability, tooling failures, dimensional nonconformance, and process capability concerns.
• Develop and optimize CNC machining strategies, cutting parameters, tooling, workholding, and fixtures for multi-axis milling, turning, grinding, and related operations; support prove-outs and production transitions.
• Interpret customer drawings, models, specifications, and contractual requirements; apply ASME Y14.5 GD&T principles to establish functional datum strategies, inspection approaches, and manufacturable process plans.
• Troubleshoot CMM and other metrology results, distinguish measurement-system issues from product variation, and work with Quality and inspection personnel to establish reliable measurement methods and disposition paths.
• Create and maintain manufacturing plans, operation sheets, work instructions, tooling requirements, routings, BOMs, item records, and other controlled engineering documentation in ERP and related systems.
• Lead technical investigation, material review support, root-cause analysis, corrective action, and recurrence prevention for internal and customer-reported nonconformances.
• Coordinate technical requirements with Quality, Operations, Program Management, Supply Chain, customers, and outside processors; ensure processes and tooling meet applicable customer, organizational, regulatory, AS9100, and Nadcap requirements.
• Manage multiple projects and production priorities, establish realistic milestones, communicate risk and status clearly to management, and drive work to closure without close day-to-day supervision.
• Support quotation and make/buy decisions through manufacturability reviews, process concepts, tooling estimates, risk identification, and technical input to cost and schedule assumptions.
• Develop process qualifications, first-article support, validation plans, and production-readiness activities as required for new or revised products and processes.
• Participate in continuous-improvement initiatives that improve safety, quality, delivery, cost, setup time, throughput, and process repeatability.
• Mentor less-experienced engineers, programmers, and technical personnel through sound problem-solving practices, process discipline, and effective communication.

Required Qualifications:

• Bachelor's degree in Manufacturing, Mechanical, Industrial, Aerospace Engineering, or a closely related discipline; equivalent combination of education and directly relevant experience may be considered.
• 10 or more years of progressive manufacturing/process engineering experience in a complex machining environment; aerospace or similarly regulated, high-mix, low-volume manufacturing experience strongly preferred. Approximately 15 years of relevant experience is preferred.
• Advanced ability to read, analyze, and apply engineering drawings, models, customer specifications, and ASME Y14.5 GD&T requirements.
• Experience with CAD/CAM systems; Siemens NX experience is preferred. Working knowledge of 3D modeling and preparation of clear, usable shop documentation is required.
• Experience with ERP systems and controlled manufacturing documentation, including routings, BOMs, work instructions, and item master records.
• Working knowledge of AS9100 quality-system expectations and aerospace special-process controls; Nadcap familiarity is preferred.
• Demonstrated ability to lead multiple technical projects, organize competing priorities, communicate concise status and risk, and deliver under production pressure.
• Clear written and verbal communication skills, with the judgment to work effectively from the shop floor through executive management and with customers or suppliers.