What are the responsibilities and job description for the Process Engineer position at Douglas Electrical Components, Inc.?
SUMMARY: The Process Engineer is responsible for developing, implementing, and continuously improving manufacturing processes to ensure they are scalable, repeatable, and capable of meeting quality, cost, and delivery objectives.
This role serves as the technical owner of assigned processes, supporting New Product Introduction (NPI), process validation, and ongoing production performance. The Process Engineer executes engineering strategies defined by leadership, ensuring processes are statistically capable, compliant with the Quality Management System (QMS), and aligned with business objectives.
Working cross-functionally with Quality, Production, Applications Engineering, and Supply Chain, this position plays a key role in driving process stability, yield improvement, scrap and rework reduction, throughput improvement, and data-driven decision-making in a high-mix, low-volume manufacturing environment.
CORE VALUES
All employees are expected to demonstrate the Company’s Core Values through daily actions, decision-making, and interactions:
- Client Oriented – Focus on developing long-term relationships, products, and services that meet client needs.
- Open – Communicate honestly and transparently about capabilities, challenges, and solutions.
- Nimble – Think critically, respond quickly, and adapt effectively to changing priorities and situations.
- Necessary – Recognize that every role contributes to organizational success and take ownership of outcomes.
- Engineering Mindset – Approach challenges by developing practical, thoughtful solutions regardless of role.
- Continuous Improvement – Actively seek opportunities to improve processes, performance, and personal development.
- Teamwork – Collaborate effectively with coworkers, leadership, vendors, and clients to achieve shared goals.
ESSENTIAL DUTIES AND RESPONSIBILITIES:
- Own and support assigned manufacturing processes, ensuring they are stable, repeatable, and capable of meeting customer, quality, and production requirements.
- Execute process development and industrialization activities from prototype through full-rate production under the direction of the Facilities & Process Engineering Manager.
- Develop and maintain process documentation including work instructions, process flows, PFMEAs, and control plans, ensuring alignment with QMS requirements.
- Establish and validate process capability using statistical methods (Cp/Cpk, DOE, SPC), ensuring processes meet defined performance criteria.
- Support successful completion of NPI deliverables including DFM/DFA, FAI, PPAP, and process validation activities.
- Monitor process performance through data collection and analysis, identifying trends and driving corrective actions to improve yield, reduce variation, and minimize cost of poor quality.
- Lead and participate in structured problem-solving activities (8D, root cause analysis) related to process issues, nonconformances, and customer concerns.
- Support implementation and maintenance of SPC and real-time process monitoring systems to enable data-driven decision-making.
- Collaborate with Quality, Production, Applications Engineering, and Supply Chain to ensure process compliance, effective implementation, and alignment with operational needs.
- Support tooling, fixture, and equipment development activities, including design input, qualification, and validation.
- Drive continuous improvement initiatives focused on increasing throughput, reducing waste, improving quality, and enhancing process robustness.
- Assist in training operators and technicians on processes, ensuring consistent execution and adherence to defined standards.
SKILLS AND ABILITIES:
- Working knowledge of process development, DFM/DFA, validation techniques, and statistical methods (DOE, Cp/Cpk, SPC) in a manufacturing environment.
- Ability to collect and analyze process data, identify trends, and make fact-based decisions to improve process performance and stability.
- Strong capability in structured problem-solving (RCA, 8D, DMAIC) to eliminate root causes and implement sustainable improvements.
- Ability to work effectively with Quality, Production, Applications Engineering, and Supply Chain to drive alignment and execution.
- Able to translate engineering direction into actionable tasks and deliver results with a high level of ownership, accountability and attention to detail.
- Strong written and verbal communication skills, with the ability to clearly present technical information at all organizational levels.
- Ability to document technical findings, process changes, and validation results clearly and accurately to support effective decision-making and compliance.
- Working knowledge of tooling, fixturing, and equipment qualification concepts, including the ability to support implementation and validation activities.
- Ability to manage process changes with strong documentation discipline, ensuring updates are controlled, communicated, and sustained in accordance with QMS requirements.
- Comfortable working in a high-mix, low-volume environment requiring flexibility, prioritization, and responsiveness.
KEY COMPETENCIES:
- Customer/Client Focus
- Accountability and Ownership
- Collaboration and Teamwork
- Adaptability and Agility
- Continuous Improvement Mindset
- Integrity and Transparency
- Solution-Oriented Thinking
- Practical Innovation
- Engineering Judgement
EDUCATION AND/OR EXPERIENCE:
- Bachelor’s in Mechanical, Manufacturing, Industrial Engineering, or related field preferred.
- 5–7 years of experience in manufacturing, process engineering, or a related technical environment.
- Experience supporting NPI, process validation, and transition from prototype to production preferred.
- Working knowledge of AS9100 and ISO 9001 requirements and their integration into manufacturing processes.
- Demonstrated experience with process capability analysis, SPC, and statistical tools.
- Must have experience in regulated industries such as aerospace, defense, or medical devices.
- Experience in high-mix, low-volume manufacturing environments is strongly preferred.
- Professional certification such as Six Sigma Green Belt, Lean Manufacturing, or equivalent is highly desirable.
- Proven track record in cross-functional collaboration to implement and sustain process improvements.
OTHER QUALIFICATIONS:
Physical Demands:
The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions.
q Ability to alternate between sitting, standing, and walking throughout the workday while supporting engineering activities in office and production areas.
q Must be able to move through manufacturing, laboratory, and office areas to observe processes, support trials, and collaborate with cross-functional teams.
q Requires frequent use of a computer and the ability to review technical drawings, process data, procedures, and reports.
q Frequent use of hands for computer work, documentation, measuring devices, and interaction with tools, fixtures, or equipment during process support activities.
q Ability to reach, bend, and maneuver as needed to observe equipment, review setups, and support validation or troubleshooting activities safely.
q Ability to communicate effectively in office and production settings, including speaking, hearing, and exchanging technical information with operators, technicians, and engineers.
q Occasional lifting or moving materials, components, fixtures, or equipment up to 20 pounds may be required.
q Physical activities may include extended computer work, shop-floor observation, participation in process trials, and movement between departments to support production and continuous improvement initiatives.
Work Environment:
The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions.
q Work is performed in both office and manufacturing environments, with regular time spent on the production floor supporting process development, validation, troubleshooting, and continuous improvement activities.
q Exposure to typical manufacturing conditions may include moderate noise, moving equipment, mechanical hazards, and use of required personal protective equipment in designated areas.
q Occasional schedule flexibility may be required to support validation activities, production trials, equipment qualifications, training, or other critical manufacturing needs; limited travel for training or supplier support may also be required.