Process Engineer

SUMMARY

Seeking a Process Engineer in San Antonio, Texas to design, optimize, and sustain manufacturing processes for metal-mechanical components and large assemblies, including welded frames, enclosures, and platforms. This role supports equipment, tooling, workflow design, process standardization, and continuous improvement to ensure efficiency, quality, and safety.

RESPONSIBILITIES

• Design and optimize plant layouts, material flow, and workstation configurations to improve efficiency and safety.
• Design and validate jigs, fixtures, gauges, assembly tooling, lift assists, and welding templates.
• Develop, analyze, and optimize manufacturing processes, and equipment for sheet metal fabrication, welding (MIG/TIG/robotic), machining, surface preparation, powder/wet coating, and mechanical/electrical assembly.
• Build and maintain PFMEAs, Control Plans, Process Flow Diagrams (PFDs), and standardized work instructions.
• Implement error-proofing (Poka-Yoke) solutions and process controls to ensure quality and consistency.
• Lead Continuous Improvement events such as Kaizen, 5S, SMED, and Value Stream Mapping (VSM).
• Partner closely with NPI Engineering for enclosures, tanks, platforms, and structural components; support the First Article Inspection (FAI) for NPIs.
• Create and release routings, validate BOMs, define tooling requirements, and develop work instructions for new products.

REQUIREMENTS

• Bachelor’s degree in mechanical, Manufacturing, Industrial Engineering, or equivalent experience.
• 4+ years of experience in manufacturing or process engineering within a metal-mechanic or enclosure manufacturing environment.
• Experience designing tooling, working with welded assemblies, sheet metal systems, and large enclosure structures.
• Proficiency with CAD tools (SolidWorks/PDM/AutoCAD).
• Knowledge of process engineering tools: PFMEA, CP, PFD, SOPs, 8D, SPC.
• Familiarity with ERP/MRP systems (Epicor, SAP, Oracle) and PLM tools.
• Skilled in time studies, takt calculations, and line balancing.
• Lean Six Sigma certification (Green Belt preferred).
• Excellent communication and collaboration across engineering, production, and leadership teams.
• Ability to drive change and lead cross-functional teams.