Sr Process Engineering Manager

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

Founded in 1944, HSM is athird generation, privately held company with a rich history of innovation and a commitment to our people. With 25 locations across the U.S. and corporate headquarters in Hickory, NC and Huntersville, NC, we specialize in manufacturing components for furniture, bedding, transportation, packaging, automotive, and healthcare industries. Our expertise also includes designing and building automated production machinery. HSM products from sofa springs to swimming pool noodles and bus seats, touch everyday life in countless ways.

At HSM, our success is built on our people. We foster a culture of teamwork, innovation, and shared success. If you’re looking for a meaningful place to grow and make an impact, we want to hear from you!

What You Will Do

• Lead Process Engineering Across Multiple Sites
  
  • Provide technical leadership and direction to Process and Manufacturing Engineering teams across multiple facilities.
  • 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, collaborative technical organization.
• Improve Manufacturing Processes
  
  • 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 engineering analysis and data-driven decision-making.
  • Advance line balancing, capacity planning, workstation design, material flow, tooling, fixtures, and ergonomic improvements.
  • Drive measurable reductions in scrap, cycle time, waste, and manufacturing cost.
• Lead New Product and Process Launches
  
  • Guide manufacturing-readiness activities from early concept through start of production.
  • Lead and support APQP deliverables, including process flow diagrams, PFMEAs, control plans, manufacturing validation, Run-at-Rate, and PPAP submissions.
  • Partner with Product Development to improve design for manufacturability, design for assembly, and production scalability.
  • Coordinate prototype builds, manufacturing trials, engineering validation, production transfers, and structured launch reviews.
• Advance Automation and Manufacturing Technology
  
  • Partner with Controls Engineering to implement equipment upgrades, automation solutions, manufacturing technologies, and capital projects.
  • Support robotics, PLC-controlled equipment, vision systems, automated inspection, data collection, production analytics, and Industry 4.0 initiatives.
  • Participate in equipment evaluation, selection, commissioning, startup, and performance monitoring.
• Drive Operational Excellence
  
  • Lead Lean Manufacturing, Kaizen, Six Sigma, VAVE, and structured problem-solving initiatives.
  • Improve OEE, process capability, and manufacturing performance across multiple facilities.
  • Apply statistical analysis, SPC, Design of Experiments, and other engineering methodologies to solve complex operational challenges.
  • Prioritize projects based on customer needs, operational performance, financial impact, and long-term business strategy.

What You Bring

Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, or a related technical discipline; master’s degree preferred.

At least eight years of progressive manufacturing or process engineering experience.

At least five years of engineering leadership experience.

Demonstrated success leading teams or engineering initiatives across multiple manufacturing facilities.

Experience in automotive, commercial transportation, specialty vehicle, recreational vehicle, or Tier 1/Tier 2 manufacturing strongly preferred.

Broad manufacturing-process expertise, including metal fabrication, MIG and laser welding, foam, cut-and-sew, and mechanical assembly.

Experience with tooling, fixtures, process validation, line balancing, capacity planning, material flow, and ergonomics.

Working knowledge of PLC-controlled equipment, robotics, automation systems, and advanced manufacturing technologies.

Strong knowledge of ISO 9001; experience with 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.

A proven ability to develop engineering talent and build high-performing teams.

Travel

• This position requires up to 30% travel to support manufacturing facilities, customer and supplier locations, production launches, audits, and strategic engineering initiatives.

Why Join Us

• Health & Wellness: Affordable medical, dental, and vision insurance plans, including an innovative global healthcare option for qualified participants.
• Retire:401(k) with company match, fully vested from day one.
• Paid Time Off: Competitive PTO: 3 Weeks of Vacation + 9 company paid holidays.
• On-Site Medical Clinics: Free for you and covered dependents.
• Teladoc: 24/7 access with no copay.
• Professional Development: Tuition reimbursement, professional development assistance and career growth opportunities.
• Discounts: Enjoy discounts with HSM partners, including Dollywood Parks & Resort, Verizon Wireless, and more.

EEOC

At HSM, we believe that our diversity creates a productive workplace. All qualified candidates will receive consideration for employment without regard to age, race, creed, color, religion, sex, national origin, ancestry, marital status, affectionate or sexual orientation, gender identity or expression, or protected veteran status and will not be discriminated against on the basis of disability.

Equal Opportunity Employer/Protected Veterans/Individuals with Disabilities
This employer is required to notify all applicants of their rights pursuant to federal employment laws.For further information, please review the Know Your Rights notice from the Department of Labor.