Senior Process Engineer
1 day ago
Waco
About FiunEx: FiunEx is a highly specialized profit improvement operation consulting and Engineering service firm,which has a proven track record in flawless execution of projects in over 25 countries. We have developed a niche in Life Sciences sector driving majority of our revenues. Through our unique engagement model and its success, we have experienced extremely tremendous growth in a short duration. We now have presence in US, Ireland, India and Thailand. For more details about the company, visit our website at _ This opportunity is for a Senior Process Project Engineer supporting transformer manufacturing operations in the USA. The role will focus on manufacturing process improvement, capital projects, equipment implementation, production efficiency and cross-functional project execution. RESPONSIBILITIES The role involves developing and improving manufacturing processes to produce high-quality transformers safely, efficiently and cost-effectively, while supporting productivity, quality, delivery and continuous improvement objectives. • Lead manufacturing and process engineering projects from initiation through completion, delivering agreed scope, cost, schedule, quality and functionality requirements., • Apply structured project-management practices across project initiation, planning, execution, monitoring, control and close-out., • Develop project documentation including requirements specifications, project charters, work breakdown structures, capital expenditure requests (CERs), project plans, budgets, schedules and risk registers., • Coordinate the design, procurement, installation, commissioning and qualification/acceptance of manufacturing equipment, tooling, fixtures and process systems., • Support process development and optimization across transformer manufacturing operations, including core processing and assembly, winding, coil assembly, insulation, tank fabrication, welding/brazing, drying, impregnation, painting, final assembly and testing, as applicable to the facility., • Work with Manufacturing, Engineering, Quality, Maintenance, Supply Chain and Operations teams to identify process constraints, improve throughput and reduce scrap, rework, downtime and manufacturing cost., • Support factory acceptance testing (FAT), site acceptance testing (SAT), equipment commissioning and production readiness activities for new or modified equipment and processes., • Use Lean Manufacturing and Six Sigma principles to optimize process flow, plant layouts, material movement, line balancing, ergonomics and overall equipment effectiveness., • Develop and implement standard work, process documentation, work instructions, process flow diagrams, control plans and other manufacturing engineering documentation., • Use quality and problem-solving tools such as Process Maps, Cause-and-Effect (C&E) analysis, FMEA, Pareto analysis, 5-Why and Design of Experiments (DOE), as appropriate, to address process issues and drive continuous improvement., • Support New Product Introduction (NPI), engineering changes, product/process transfers and production ramp-up activities., • Partner with Quality and Operations teams to investigate manufacturing issues and implement effective corrective and preventive actions., • Ensure appropriate change-control, engineering-change and project documentation is completed and maintained for manufacturing projects., • Track and report project progress, risks, actions, costs and key performance indicators to Engineering and Operations leadership and other stakeholders., • Manage multiple projects simultaneously and effectively prioritize resources, timelines and deliverables., • Work with vendors, contractors and equipment suppliers; review technical proposals, specifications, layouts and equipment documentation and coordinate activities through installation and start-up., • Supervise and provide technical direction to junior engineers, technicians and subcontractors, ensuring effective communication and timely execution., • Support plant start-up, production ramp-up, shutdown and major equipment installation activities while minimizing disruption to production., • Promote safe working practices and comply with plant EHS policies, procedures, PPE requirements and applicable safety standards., • Support manufacturing quality requirements and applicable industry, customer and company standards relevant to transformer production., • Provide weekly/monthly operational excellence and project updates, including key metrics, project status, risks, savings and improvement actions. DESIRED SKILLS AND EXPERIENCE • Minimum 8 years of relevant and recent experience in process engineering, manufacturing engineering and/or project engineering within an industrial manufacturing environment; experience in transformer manufacturing is highly desirable., • Bachelor’s degree in Mechanical, Electrical, Industrial, Manufacturing Engineering or a related engineering discipline., • Strong analytical, technical problem-solving and project-management skills., • Demonstrated ability to independently manage projects while leading cross-functional teams., • Hands-on experience with manufacturing processes, equipment implementation, process improvement and production engineering., • Understanding of transformer manufacturing processes such as core cutting/stacking, winding, coil assembly, insulation, tank fabrication, welding/brazing, drying/impregnation, painting, assembly and electrical/mechanical testing, as applicable., • Experience with capital equipment projects, equipment installation, commissioning, FAT/SAT and production start-up., • Strong knowledge of Lean Manufacturing and Six Sigma methodologies and their practical application in a production environment., • Working knowledge of manufacturing quality tools including PFMEA/FMEA, process mapping, root-cause analysis, control plans, SPC and DOE., • Experience supporting NPI, product transfers, engineering changes and manufacturing process development., • Ability to develop and maintain engineering and manufacturing documentation, including process specifications, work instructions, project plans and equipment documentation., • Strong communication and stakeholder-management skills, with the ability to work effectively with customers, vendors, contractors and cross-functional teams., • Experience leading or participating in manufacturing audits and continuous-improvement initiatives., • Technical proficiency with modern manufacturing, automation and process technologies., • Strong understanding of production planning, capacity improvement, material flow, line balancing and equipment utilization., • Sound technical engineering approach to project execution, risk management and problem solving., • Proficiency with Microsoft Office applications, including Excel, Word and PowerPoint; experience with project-planning tools is desirable. KEY COMPETENCIES • Project Planning & Execution, • Manufacturing Process Engineering, • Transformer Manufacturing Processes, • Capital Equipment & CAPEX Projects, • Lean Manufacturing & Continuous Improvement, • Root Cause Analysis & Problem Solving, • Cross-Functional Team Leadership, • Vendor & Contractor Management, • Process Documentation & Change Management, • Safety, Quality & Operational Excellence EDUCATION Bachelor’s degree in Mechanical, Electrical, Industrial, Manufacturing Engineering or a related engineering discipline. Advanced technical qualifications or Lean/Six Sigma certification are an advantage.