What are the responsibilities and job description for the Sr. Manufacturing Process Engineer position at Barnes Aerospace?
Essential Responsibilities
- Independently plan, develop, implement, validate, and continuously improve manufacturing processes for complex aerospace components, including machining, welding, heat treatment, EDM, plasma spray, NDT, and other special processes.
- Provide decisive, responsive shop-floor engineering support for production interruptions, setup issues, machining instability, tooling failures, dimensional nonconformance, and process capability concerns.
- Develop and optimize CNC machining strategies, cutting parameters, tooling, workholding, and fixtures for multi-axis milling, turning, grinding, and related operations; support prove-outs and production transitions.
- Interpret customer drawings, models, specifications, and contractual requirements; apply ASME Y14.5 GD&T principles to establish functional datum strategies, inspection approaches, and manufacturable process plans.
- Troubleshoot CMM and other metrology results, distinguish measurement-system issues from product variation, and work with Quality and inspection personnel to establish reliable measurement methods and disposition paths.
- Create and maintain manufacturing plans, operation sheets, work instructions, tooling requirements, routings, BOMs, item records, and other controlled engineering documentation in ERP and related systems.
- Lead technical investigation, material review support, root-cause analysis, corrective action, and recurrence prevention for internal and customer-reported nonconformances.
- Coordinate technical requirements with Quality, Operations, Program Management, Supply Chain, customers, and outside processors; ensure processes and tooling meet applicable customer, organizational, regulatory, AS9100, and Nadcap requirements.
- Manage multiple projects and production priorities, establish realistic milestones, communicate risk and status clearly to management, and drive work to closure without close day-to-day supervision.
- Support quotation and make/buy decisions through manufacturability reviews, process concepts, tooling estimates, risk identification, and technical input to cost and schedule assumptions.
- Develop process qualifications, first-article support, validation plans, and production-readiness activities as required for new or revised products and processes.
- Participate in continuous-improvement initiatives that improve safety, quality, delivery, cost, setup time, throughput, and process repeatability.
- Mentor less-experienced engineers, programmers, and technical personnel through sound problem-solving practices, process discipline, and effective communication.
- Bachelor's degree in Manufacturing, Mechanical, Industrial, Aerospace Engineering, or a closely related discipline; equivalent combination of education and directly relevant experience may be considered.
- 10 or more years of progressive manufacturing/process engineering experience in a complex machining environment; aerospace or similarly regulated, high-mix, low-volume manufacturing experience strongly preferred. Approximately 15 years of relevant experience is preferred.
- Advanced ability to read, analyze, and apply engineering drawings, models, customer specifications, and ASME Y14.5 GD&T requirements.
- Experience with CAD/CAM systems; Siemens NX experience is preferred. Working knowledge of 3D modeling and preparation of clear, usable shop documentation is required.
- Experience with ERP systems and controlled manufacturing documentation, including routings, BOMs, work instructions, and item master records.
- Working knowledge of AS9100 quality-system expectations and aerospace special-process controls; Nadcap familiarity is preferred.
- Demonstrated ability to lead multiple technical projects, organize competing priorities, communicate concise status and risk, and deliver under production pressure.
- Clear written and verbal communication skills, with the judgment to work effectively from the shop floor through executive management and with customers or suppliers.