Senior Process Engineer

Description

About Us

Real Flame® is a family-owned company based in Racine, Wisconsin with a team of approximately 40 employees. We specialize in the design, production, and sale of indoor electric fireplaces, outdoor fire features, and outdoor furniture. For more than 25 years, our mission has remained simple: to create beautifully designed, high-quality, and safe fire features that allow consumers to experience the charm and comfort of a fireplace without the hassle.

As a pioneer in the early gel fuel industry, Real Flame later introduced the VividFlame electric firebox, helping shape today’s electric fireplace category. Since then, we have expanded our product offerings to include outdoor gas fire tables and bowls, wood-burning fire pits, and outdoor furniture.

Despite our growth, we have remained a close-knit, agile team that values collaboration, accountability, and innovation. We continue to design our products in-house and bring new styles to market each year. Today, Real Flame products can be found in hundreds of thousands of homes, and we’re proud of the role we play in helping customers create meaningful moments with family and friends.

What You'll Be Doing 

The Senior Process Engineer is responsible for ensuring that Real Flame's engineering processes, product development procedures, and product launch requirements are consistently followed across all new product programs. The Senior Process Engineer acts as the "process authority" for the Engineering team, ensuring projects advance through established engineering milestones and checks, required reviews are completed, documentation is accurate, and cross-functional deliverables are met before progressing to the next stage of development.

Working closely with Product Design Engineers, Product Development, Quality, Purchasing, Sourcing, Manufacturing Partners, and Sales, this role provides independent oversight of new product development activities while driving continuous improvement of engineering standards, launch processes, and operational workflows. The ideal candidate combines strong engineering judgment, project management capabilities, manufacturing knowledge, and process discipline to ensure every product is developed, reviewed, documented, and launched in accordance with Real Flame standards.

Essential Functions

Product Development Process Ownership

• Ensure all engineering milestones, redlines, reviews, and launch requirements are completed prior to project advancement
• Monitor project compliance with established development timelines and engineering workflows
• Track project status and identify gaps, risks, or missing deliverables that could impact launch readiness
• Drive accountability for completion of required engineering documentation throughout the development cycle
• Own the engineering change order (ECO) and change-control process, including documentation and approval
• Report on process adoption and effectiveness to the Director, Design & Engineering
• Develop, maintain, and improve engineering standard operating procedures (SOPs)
• Provide training and guidance regarding engineering procedures and best practices

Engineering Review & Product Validation

• Lead formal engineering process reviews throughout concept, prototype, sample, and launch phases
• Ensure print packets, BOMs, specifications, and supporting documentation meet GD&T and company standards
• Verify that engineering deliverables align with approved project requirements and customer expectations
• Coordinate engineering signoffs and approvals required for project progression
• Partner with Design Engineering teams to identify and resolve technical risks prior to production

Continuous Improvement

• Lead initiatives focused on improving speed, quality, and effectiveness of the product development process
• Analyze project performance metrics and identify opportunities for efficiency improvements
• Develop KPI dashboards related to engineering process compliance, launch readiness, and project execution
• Implement Lean Manufacturing, Design for Manufacturing (DFM), DFEMA, and Design for Assembly (DFA) best practices where appropriate
• Evaluate and improve workflow systems, documentation standards, and communication processes

Systems & Technical Competencies

Engineering Systems

• SolidWorks
• SolidWorks PDM
• NetSuite
• Global Shop ERP
• Airtable
• Microsoft Office Suite
• Adobe Creative Suite

Requirements

• Bachelor's Degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, Process Engineering, or related technical discipline
• 3-6 years of experience in product development, manufacturing engineering, process engineering, or new product introduction roles
• Experience working within stage-gate or structured product development systems
• Strong understanding of manufacturing processes associated with furniture, outdoor living products, fabricated metal products, or consumer products
• Experience managing cross-functional projects involving suppliers, quality, engineering, and sourcing teams
• Strong organizational and project management skills
• Excellent verbal and written communication abilities
• Ability to identify process inefficiencies and implement sustainable improvements
• Ability to work independently while managing multiple projects simultaneously

Preferred Qualifications

• Experience in furniture manufacturing, outdoor furniture, fireplaces, fire tables, or consumer durable goods
• Certification or formal training in Lean Manufacturing, Six Sigma, or Continuous Improvement methodologies
• Experience working with international suppliers and manufacturing partners
• Familiarity with certification programs including UL, CSA, CE, or related standards
• Experience implementing ERP or PLM/PDM workflow improvements

Why You'll Love this Opportunity 

• Play a key role in shaping how new products move from concept to launch
• Influence engineering standards, processes, and best practices across the organization
• Work directly with senior leadership and cross-functional teams in a highly visible role
• Make a measurable impact in a growing company where decisions happen quickly and ideas are put into action
• Be part of a team that designs innovative consumer products found in homes across North America

Career Growth Opportunity 

This role is ideal for an engineer who enjoys building structure, improving processes, and driving accountability across product development. You'll have the opportunity to influence how Real Flame develops products for years to come while expanding your leadership, project management, and operational excellence expertise.

Who Succeeds at Real Flame You will thrive in this role if you:

• Enjoy creating structure and accountability within complex projects
• Like balancing technical engineering work with process improvement initiatives
• Are comfortable working cross-functionally with global suppliers and manufacturing partners
• Take ownership, communicate effectively, and follow through on commitments
• Are energized by solving problems and continuously improving how work gets done

 Benefits & Perks 

• Competitive base salary plus profit sharing and individual performance incentive bonus
• Comprehensive medical, dental, and vision plans
• Company-funded deductible reimbursement up to $1,000 (individual) / $2,000 (family)
• 401(k) with company match up to 4%
• Up to 6 weeks of paid parental leave
• Generous paid time off and company holidays
• Friday work-from-home flexibility following onboarding
• Employee Assistance Program (EAP)
• Company-paid life and disability insurance
• Employee product discount
• Regular team-building events and company-sponsored outings
• Direct access to leadership and the opportunity to make a meaningful impact on company growth and success
• Collaborative, entrepreneurial culture where your ideas are valued and implemented

Work Authorization:
Real Flame does not sponsor employment visas now or in the future. Applicants must be legally authorized to work in the United States without the need for current or future sponsorship.

Recruiting Agencies:
Real Flame does not accept unsolicited resumes from staffing agencies, recruiting firms, or search agencies. Any unsolicited resumes submitted to Real Flame employees or through our application process will become the property of Real Flame, and no fee will be paid if the candidate is hired.