Staff Process Engineer

Ultimate Staffing; Durham (NC); On-site; USD 100,000 - 160,000; Full time

Job summary

Ultimate Staffing Services in Durham, NC, seeks a Staff Process Engineer to lead the development and scaling of complex manufacturing processes from pilot stages to high-volume production. You will drive DOE studies, SPC and MSA analyses, and PFMEA development while mentoring engineers on process optimization.

The role emphasizes leadership, documentation, and strong analytical skills in a fast-paced, safety-conscious environment with travel to supplier sites as needed.

Qualifications

• Degree in engineering or related field with 7+ years of process/manufacturing experience.
• Hands-on experience taking processes from development through commissioning and high-volume production.
• Deep knowledge of DoE, SPC, MSA, Gage R&R, Cp/Cpk, Pp/Ppk, ANOVA, regression, and statistical process analysis.
• Experience in PFMEAs, Control Plans, Process Flows, and manufacturing documentation.
• Troubleshooting complex equipment and process problems on the shop floor.
• Preference for Six Sigma Green Belt or Black Belt and familiarity with Minitab/JMP.

Responsibilities

• Develop equipment recipes, process parameters, operating windows, and production standards.
• Design and execute DoEs, analyze main effects/interactions, ANOVA, regression, and optimize critical CPPs.
• Support FAT/SAT, equipment startup, engineering trials, qualification runs, and ramp.
• Perform Cp/Cpk, Pp/Ppk, SPC, control-chart, and process stability analysis.
• Lead MSA and Gage R&R studies to verify measurement repeatability and reproducibility.
• Develop and own PFMEAs, Control Plans, Process Flows, and SOPs.
• Lead structured problem solving using 5-Why, Fishbone, Pareto, 8D, hypothesis testing.
• Improve FPY, scrap, rework, cycle time, OEE, throughput, and process capability.
• Identify CTQs/CPPs and establish monitoring, control limits, sampling plans, and reaction plans.
• Mentor engineers and review DoEs, PFMEAs, capability studies, and technical investigations.

Skills

DoE

SPC

MSA

Gage R&R

Cp/Cpk

Pp/Ppk

ANOVA

Regression analysis

PFMEA

Control Plans

Process Flows

SOPs

Supervision

Manufacturing documentation

Education

Bachelor's degree in Engineering, Materials Science, or related technical field

Tools

Minitab

JMP

Job description

Position Overview

Ultimate Staffing Services is actively seeking a Staff Process Engineer for a leading manufacturing company located in Durham, North Carolina. The company is dedicated to producing American rare-earth permanent magnets, focusing on national security and economic resiliency by serving critical industries such as defense, aerospace, and automotive. This position offers an exciting opportunity to work in a dynamic and innovative environment, providing technical leadership to develop and scale complex manufacturing processes from pilot-scale development to high-volume production.

Responsibilities

• Develop equipment recipes, process parameters, operating windows, and production standards.
• Design and execute DoEs, analyze main effects/interactions, ANOVA, regression, and optimize critical process parameters.
• Support FAT/SAT, equipment startup, engineering trials, qualification runs, and production ramp.
• Perform Cp/Cpk, Pp/Ppk, SPC, control-chart, and process stability analysis.
• Lead MSA and Gage R&R studies to verify measurement repeatability and reproducibility.
• Develop and own Process Flows, PFMEA, Control Plans, BOP, Process Sheets, SOPs, Work Instructions, and Reaction Plans.
• Lead structured problem solving using 5-Why, Fishbone, Pareto, 8D, hypothesis testing, and statistical analysis.
• Improve FPY, scrap, rework, cycle time, OEE, throughput, and process capability.
• Identify CTQs and Critical Process Parameters (CPPs) and establish monitoring, control limits, sampling plans, and reaction plans.
• Mentor engineers and review DoEs, PFMEAs, capability studies, process specifications, and technical investigations.

Qualifications

• Bachelor's degree in Engineering, Materials Science, or related technical field with 7+ years of process/manufacturing engineering experience.
• Strong hands-on experience taking processes from development through commissioning, qualification, and high-volume production.
• Deep knowledge of DoE, SPC, MSA, Gage R&R, Cp/Cpk, Pp/Ppk, ANOVA, regression, and statistical process analysis.
• Strong experience developing PFMEAs, Control Plans, Process Flows, Process Specifications, and manufacturing documentation.
• Proven ability to troubleshoot complex equipment and process problems on the manufacturing floor.
• Experience with statistical tools such as Minitab or JMP preferred.
• Six Sigma Green Belt or Black Belt preferred.
• Experience in metallurgy, advanced materials, powder processing, high-temperature processing, automotive, aerospace, or other high-volume manufacturing preferred.
• Must be a U.S. Person due to required access to U.S. export-controlled information or facilities.

Required Work Hours

The position requires work from Monday to Friday during 1st shift hours.

Benefits

The role offers a competitive salary range between $100,000 and $160,000 per year. The position involves around 25% travel time to equipment suppliers for design reviews, engineering trials, Factory Acceptance Tests (FAT), and commissioning support.

Additional Details

This is a supervisory position, offering an opportunity for leadership and professional growth within a company committed to technical excellence and transparency.

All qualified applicants will receive consideration for employment without regard to race, color, national origin, age, ancestry, religion, sex, sexual orientation, gender identity, gender expression, marital status, disability, medical condition, genetic information, pregnancy, or military or veteran status. We consider all qualified applicants, including those with criminal histories, in a manner consistent with state and local laws, including the California Fair Chance Act, City of Los Angeles' Fair Chance Initiative for Hiring Ordinance, Los Angeles County Fair Chance Ordinance, and San Francisco Fair Chance Ordinance.