Capstan Atlantic, an employee owned company, seeks to be the highest quality supplier of sintered metal gears in the world and to continue a rigorous quality system that maintains our world’s best quality reputation. We are looking for an experienced Senior Process Development Engineer to join our growing team in Wrentham, MA.
PRIMARY FUNCTION:
The Senior Process Development Engineer works with a team and is responsible for the development of a process to manufacture powder metal components that will result in good quality parts during mass production, that are produced on time and at the quoted manufacturing margin. They are responsible for the scheduling of production validation runs, verifying that sample parts are manufactured to customer and internal requirements, completing all necessary documentation and submitting samples parts and documentation (PPAP) to the customer. The Senior Process Development Engineer is responsible for evaluating risk in the process and making process / part improvements that may originate from process capability, input from production personnel, feedback from the customer, customer concerns, or other areas.
DUTIES AND RESPONSIBILITIES:
The following is a brief description of some of the duties and responsibilities (not limited to the following):
A. Member of APQP team to understand the manufacturing process, timing, internal and external requirements, and evaluate risk for new or revised products.
B. Product Manager for the development of new products and follow parts through the sample verification run to make sure parts are good quality, on time and meet all customer requirements.
C. Perform studies on the parts / process that may include capability studies, size change studies, measurement system studies.
D. Document the process and rates in the margin analysis, excel work instruction files and in the ERP system.
E. Develop necessary internal documentation (includes, but not limited to: Timing charts, Process Flow Diagrams, Control Plans, PFMEAs, Work Instructions, Shipping/Label documentation, departmental procedures, etc).
F. Specify and procure any gages/equipment/ packaging etc. needed to produce and/or ship product. Create instructions for new gages/equipment and train production personnel.
G. Review process capability results from first run and update or revise documentation where required. Inspect or have inspected product from first run to understand product conformance and process capability.
H. Develop and submit any necessary external customer documentation (PPAP, GR&R, IMDS, etc.).
I. Lead Production Readiness meetings to release jobs to manufacturing.
J. Handles assigned nonconformities and corrective actions as assigned from MRR meetings, customer spills, internal audits or team requests. Completes documentation as required.
K. Incorporate ECO’s for assigned products.
L. Follow jobs into production for the purpose of continuous improvement and scrap reduction.
M. Process development with outside vendors. Downflow customer requirements to the outside vendors and ensure the outside vendor process will be able to produce parts to the customer’s requirements.
TECHNICAL EXPERTISE:
The following is a brief description of the technical skills and experience required:
A- Bachelor’s degree in engineering and a minimum of 5+ years of engineering experience.
B- Proficient in Excel including the use of tables, graphs and filters to collect and analyze data.
C- Read and interpret blueprints, including GD&T.
D- Familiarity with quality measuring tools (micrometers, indicator, CMM, M&M, hardness & density testing, etc.).
E- Strong customer communication skills.
F- Strong problem-solving techniques.
G- Experience in machining or metal forming operations.
H- General materials knowledge.
I- Familiarity with ISO 9000 or IATF 16949 quality standards preferred.
J- Proficiency in statistics, data analytics and DOE preferred.
Job Type: Full-time
Benefits:
- 401(k)
- 401(k) matching
- Dental insurance
- Health insurance
- Life insurance
- Paid time off
- Tuition reimbursement
- Vision insurance
Experience level:
Schedule:
Work setting:
- In-person
- Manufacturing facility
Ability to Relocate:
- Wrentham, MA 02093: Relocate before starting work (Required)
Work Location: In person