Staff Process Engineer: Scale-Up Magnets Manufacturing

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

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.