Gear Machining Process Engineer - Automotive (Gear Machining)

Job Title: Gear Machining Process EngineerWork Location: Sterling Heights, MI Job description: Overview / SummaryWe are seeking a Gear Machining Process Engineer to support manufacturing process engineering activities for gear machining operations. The role focuses on process improvement, quality compliance, manufacturing efficiency, launch support, and continuous improvement initiatives in a high-volume manufacturing environment.Key ResponsibilitiesSupport manufacturing process engineering activities for gear machining operationsDrive continuous improvement initiatives related to safety, quality, and productivityComplete PPAP quality launch documentationApply engineering principles and analytical techniques to improve manufacturing processes and productsInvestigate manufacturing and supplier process issues and implement corrective actionsLead and conduct process audits to ensure compliance with manufacturing guidelinesConduct ergonomic evaluations and implement corrective actions as neededDevelop process documentation and work instruction sheets supporting quality methods and processesSupport capable process and tooling implementation for gear machining operationsLead variability reduction and lean manufacturing initiativesEnsure compliance with plant, corporate, governmental, and environmental standardsSupport ISO 14001 compliance and internal audit activitiesIdentify throughput constraints and implement root cause improvements to meet production targetsRequired QualificationsHigh School Diploma or GED5+ years of related manufacturing engineering experienceExperience with lean manufacturing principlesKnowledge of manufacturing engineering and manufacturing processesStrong leadership, communication, and teamwork skillsExperience supporting quality and process improvement initiativesAbility to work in a fully onsite environmentMust be legally authorized to work in the United States without sponsorshipPreferred QualificationsBachelor’s DegreeExperience with corrective and preventive action (CAPA)Knowledge of quality control methodologiesSix Sigma methodology experienceUnderstanding of hypoid bevel gear processes including blanking, milling, grinding, heat treat, shot peening, and lappingExperience with quality assessment tools such as QDAS and MinitabExperience using gear CMM equipmentExperience with 8D and 5 Why problem-solving methodologiesKnowledge of lean tools including 5S, Kanban, Poka-yoke, and Value Stream MappingExperience with DMAIC and DMADV methodologiesExperience with FMEA, PPAP, and DOE processes.