Sr. Manufacturing Process Engineer

BARNES; Warren (MI); On-site; USD 110,000 - 150,000; Full time

Job summary

BARNES in Warren, MI, seeks an experienced Manufacturing/Process Engineer to design and optimize aerospace production processes. You will lead cross-functional efforts on machining, welding, heat treatment, and other special processes, ensuring GD&T compliance and robust manufacturability.

You will drive continuous improvement, mentor junior engineers, and coordinate with Quality, Program Management, and suppliers to meet AS9100/Nadcap requirements while delivering quality, cost, and schedule

Qualifications

• Bachelor's degree required; equivalent combination of education and directly relevant experience may be considered.
• 10+ years of progressive manufacturing/process engineering experience in a complex machining environment; aerospace or regulated experience 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 preferred; 3D modeling and clear shop documentation 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; Nadcap familiarity preferred.
• Demonstrated ability to lead multiple technical projects, organize priorities, communicate status and risk, and deliver under production pressure.
• Excellent written and verbal communication skills, able to interact from shop floor to executive management and with customers.

Responsibilities

• Independently plan, develop, implement, validate, and improve manufacturing processes for aerospace components.
• Provide shop-floor engineering support for interruptions, setup issues, and process capability concerns.
• Develop CNC strategies, tooling, workholding, and fixtures for multi-axis operations; support transitions.
• Interpret drawings, ASME Y14.5 GD&T, and contractual requirements; establish manufacturable process plans.
• Troubleshoot metrology results; coordinate with Quality to establish reliable measurement methods and dispositions.
• Create and maintain manufacturing docs in ERP and related systems.
• Lead technical investigations, root-cause analysis, corrective actions, and recurrence prevention.
• Coordinate requirements with Quality, Operations, Program Management, Supply Chain, customers, and outside processors.
• Manage multiple projects and communicate risk/status; drive work to closure without close supervision.
• Support quotes and make/buy decisions via manufacturability reviews and tooling estimates.
• Develop process qualifications and production-readiness activities for new or revised products.
• Participate in continuous-improvement initiatives to improve safety, quality, delivery, cost, and throughput.
• Mentor less-experienced engineers and technicians through problem-solving and process discipline.

Skills

Reading and interpreting engineering

ASME Y14.5 GD&T knowledge

Leadership of technical projects

Clear written and verbal communication

Problem solving / root cause analysis

Education

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

Tools

Siemens NX

CAD/CAM systems

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.

Equal Opportunity Employer

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