Sr Process Engineering Manager

HSM; Huntersville (NC); On-site; USD 110,000 - 150,000; Full time

Benefits offered by this job

Health & Wellness

401(k) with company match

Paid time off

On-site medical clinics

Teladoc

Professional development

Employee discounts

Job summary

HSM in North Carolina is seeking a Senior Process Engineer to Lead Process Engineering Across Multiple Sites and drive manufacturing excellence. You will provide technical leadership to Process and Manufacturing Engineering teams, establish consistent methods, and improve performance across facilities.

You will lead new product and process launches, advance automation, support APQP/PPAP deliverables, and partner with Product Development to improve manufacturability.

Qualifications

• 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.

Responsibilities

• Lead Process Engineering Across Multiple Sites: Provide technical leadership and direction to Process and Manufacturing Engineering teams across multiple facilities; establish consistent engineering methods and performance metrics; strengthen process capability and manufacturing performance.
• Improve Manufacturing Processes: Develop, validate, optimize, and standardize processes across metal fabrication, welding, foam, cut-and-sew, and final assembly; drive safety, quality, throughput, and efficiency.
• Lead New Product and Process Launches: Guide manufacturing-readiness activities from concept through start of production; lead APQP deliverables and collaborate to improve design for manufacturability and production scalability.
• Advance Automation and Manufacturing Technology: Partner with Controls Engineering on equipment upgrades, automation solutions, and Industry 4.0 initiatives; support robotics and data analytics.
• Drive Operational Excellence: Lead Lean, Kaizen, Six Sigma initiatives; improve OEE; apply statistical methods to solve complex operational challenges; prioritize projects by customer needs and strategic impact.

Skills

Process engineering leadership

Manufacturing engineering

APQP / PFMEA

ISO 9001 knowledge

Project management

Data-driven decision making

Automation and robotics

Communication skills

Education

Bachelor’s degree in Mechanical Engineering

Master’s degree preferred

Tools

PLC systems

Robotics

Automation hardware

Minitab / SPC

Job description

HSM Company History |HSM HEART Company Values |Who is HSM to our customers?

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