Sr. Process Engineer - Aluminum Extrusion

shapecareers; Trenton (OH); On-site; USD 90,000 - 130,000; Full time

Job summary

Shape seeks an experienced Aluminum Extrusion Process Engineer to lead optimization across billet loading, extrusion, downstream processing, and heat treatment. You will drive scrap reduction, support new product introductions, and develop manufacturing process plans while mentoring extrusion experts on the shop floor.

Strong problem-solving, data analysis, and cross-functional collaboration are essential. This role requires 7+ years of relevant experience and familiarity with DOE, PFMEA, and

Qualifications

• Engineering degree from an accredited institution; 7+ years of professional engineering experience required.
• Master’s degree with 3+ years of experience preferred.
• Familiar with weld verification methods, weld testing, and measuring devices.
• Must be ITAR compliant.
• Fundamental understanding of statistics (SPC) and Six Sigma methodology.

Responsibilities

• Lead process optimization across entire aluminum extrusion lifecycle.
• Drive scrap reduction, quality improvement, and throughput.
• Provide technical authority for extrusion processes and mentor shop floor staff.
• Support new product introductions and maturation plans.
• Lead troubleshooting and continuous improvement activities on the manufacturing floor.
• Collaborate with operations and cross-functional teams to meet targets.

Skills

DOE experience

Weld verification methods

ITAR compliance

Six Sigma

Statistical methods (SPC)

MS Office (Word/Excel)

Travel up to 10%

Education

Engineering or Engineering Technology degree

Master’s Degree in Engineering (3+ yrs)

Job description

Position Summary

We're partnering with an industry leader supporting some of the most advanced aerospace & launch vehicle programs in the world and are seeking an experienced Aluminum Extrusion Process Engineer to join their manufacturing team. This role is responsible for driving process optimization, continuous improvement, and manufacturing excellence across the full aluminum extrusion lifecycle, including billet loading, extrusion, downstream processing, and heat treatment. The successful candidate will lead scrap reduction initiatives, support new product introductions, develop manufacturing process plans, and partner closely with operations to improve performance, quality, and throughput. This position serves as the technical authority for extrusion processes and will provide guidance to shop floor personnel while directing the efforts of Extrusion Process Experts responsible for troubleshooting, data collection, and day-to-day process suppor t.

Essential Job Functions include, but not limited to, the following:

• General – Applies to all Process Engineers
  • Read and interpret CAD data, blueprints, GD&T, CMM reports, customer dimensional specifications.
  • Share lessons learned proactively and also train other engineers on process improvments.
  • Provide process design and improvements in a cost efficient manner.
  • Proficient in completing cost justifications with acceptable ROI.
  • Responsible for safety in process design and in execution of daily activities.
  • Ensure compliance of practices, procedures and instructions relative to applicable corporate standards (ISO, TS, etc).
  • Ensure quality outputs from daily activities.
    • Use of proper data collection and analysis to ensure provided information is supported with data that reinforces the stated output.
    • Coordinate/facilitate/analyze process design of experiments (DOE’s).
  • Ensure timely execution of planned activities.
• Foster good working relationship and demonstrate effective communication skills with vendors, team members, suppliers and project teams.
• Manage large projects and/or large volume of projects; provides strategic support.
• Ability to oversee the work of other engineers; provide direction, feedback and mentoring.
• Independently develop approaches to projects; supervision is in the form of general discussions about desired results.
• Determine the technical objectives of assignments.
• Demonstrate proven ability to apply advanced engineering principles.
• Understand the impact of one’s decisions on other areas of the business; work broadly across the organization by interacting with multiple engineering disciplines.
• Embrace lifelong learning and Identify when it is necessary to acquire new knowledge and skills; take self-driven action to develop professionally.
• Demonstrate an interest in learning about new and emerging tools and technology.
• Recognized as a leader in problem solving of complex problems; mentor others by teaching engineering knowledge and skills.
• Skillfully use logic and analysis to identify the strengths and weaknesses, the costs and benefits and the short- and long-term consequences of different approaches.
• Continuously act to prevent problems, pursue opportunities and improve system performance.
• Develop innovative methods of obtaining or using resources when sufficient resources are not available.
• Additional functions not specifically outlined in this position description as directed by the leader.
• Functional Priority – Process Engineers will focus within one or more functional priority

• Launch & Manufacturing Support
  • Support manufacturing production by leading troubleshooting and continuous improvement activities.
  • Support plant problem solving teams to ensure the production of quality parts and a safe working environment.
  • Provide on-call support for all manufacturing processes in order to meet customer demands, when necessary.
  • Develop maturation plans and timelines in accordance with risk mitigation strategies.
  • Lead activities to launch new business and execute the maturation process.
  • Participate in regular launch team meetings.
  • Lead technical solutions and provide input and support for tool designs and development.
  • Participate in Process Failure Mode Effects & Analysis (PFMEA) development meetings.
  • Provide the specification for and procure capital needed to support new business.
  • Communicate and share information with peers to ensure launching practices are standard.
  • Continuously challenge maturation activities and identify opportunities to reduce maturation time.
  • Participate in fill and warp simulations.

• New Business Pursuit
  • Lead activities associated with winning new business.
  • Participate in Feasibility and Process Plan and Tolerance Reviews (PPTAR).
  • Provide quotes in the agreed upon timing.
  • Identify opportunities to reduce quoting, feasibility and PPTAR times.
  • Communicate and share information with global peers to ensure quoting practices are standard.
  • Engage in investigation of methods to achieve a competitive process and “win” business.
  • Ensure successful transition of value stream to Launch Engineer by sharing pertinent information developed during the quoting process.
  • Ensure Minimum Process Requirements (MPR) are accurate and relevant.

• Process Advancement
  • Lead strategic process advancement projects (“Funnel Projects”).
  • Develop project charter with defined milestone dates, including anticipated cost and timing.
  • Execute funnel projects and successfully meet cost and timing targets.
  • Implement new products and processes into manufacturing following the Machine Development process.
  • Develop specifications for new capital equipment.
  • Identify new technology, develop expertise and industry knowledge in relevant processes and communicate to the organization as necessary.

• Advanced Process Development
  • Define new opportunities in manufacturing processes to reduce cost or increase design flexibility.
  • Brainstorm, explore and objectively evaluate manufacturing processes and technologies that could add value to the organization.
  • Develop new manufacturing technologies integrated with manufacturing process using FMEA, SPC, DFSS, DVPR and others and conduct all testing necessary to validate the new technology.
  • Implement new manufacturing technologies to the product engineering teams through the release of design guidelines, training modules and sales materials.
  • Develop new materials with strategic suppliers to support Shape's global manufacturing footprint.
  • Attend and participate in domestic and global conferences and seminars on structural engineering, materials and manufacturing.
  • Work with the Business Unit teams and their customers to develop relationships and gain confidence in Shape's abilty to process advanced materials.
  • Express thoughts clearly and present technical details of our design concepts, materials and processing technologies.
  • Support day to day problem solving with the Product Engineers & Manufacturing as needed.

Position Skills and Experience Requirements

To perform this job successfully, an individual must be able to perform each essential duty effectively. The requirements listed below are representative of the knowledge, skill and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform essential job functions.

• Education/Experience
  • Engineering or Engineering Technology Degree from an accredited institution with 7+ years of professional engineering experience
  • Master’s Degree in Engineering with 3+ years of professional engineering experience
  • Familiar with weld verification methods, weld testing methodology, and measuring devices.
• Experience with conducting DOE.
• Must be ITAR compliant
• Fundamental understanding of statistics (SPC, etc.).
• Familiar with Six Sigma process.
• Proficient with Microsoft Office applications, including Word, Excel, Outlook, etc.
• Travel is occasionally required, up to 10% of the time.