Process Design Engineer

Where would you like to shape the success of your future career: At a worldwide leading manufacturer of process measuring and control technology? In a family- owned company that values its more than 3,700 employees in more than 30 countries and sees them all as individuals? In a team that breaks new ground with courage and passion? 

Did you answer „Yes“ three times? Then it is time for us to make your acquaintance. 

RESPONSIBILITIES:

CNC Machining Process Ownership:

• Own the value stream processes for CNC machining of systems and standard components, from raw stock to finished part release.
• Drive spindle time optimization across turning, milling, and multi-axis machining cells; eliminate unplanned idle time and non-cutting activity.
• Conduct and lead time studies, cycle time analysis, and capacity modeling to identify constraints and quantify improvement opportunity.
• Own and continuously improve machine scheduling practices using SAP CM25 (now deployed in Fiori); ensure accurate, realistic scheduling that supports delivery commitments without creating hidden capacity loss.
• Champion use of the Siemens TMGR Tool Manager for tool presetting, tool life management, and structured tool building,  building the discipline that makes changeovers predictable and fast.
• Define and enforce setup standards: part setup, work-holding, first-article verification, and handover documentation between shifts and operators.
• Analyze and reduce machine downtime; drive OEE improvement using SI04 and SI01 (SYNCHRO Simplifier modules) as primary visibility tools.
• Partner with programmers on CAM strategy improvements , , speeds, toolpath efficiency, and verified simulation via Vericut where applicable.
• Lead root cause analysis on scrap, rework, and non-conformances originating in machining; own corrective actions through to verified closure.

Continuous Improvement & Lean Manufacturing

• Serve as the Huntersville site's SYNCHRO+ lead for the Manufacturing area (CNC, fabrication, welding), working as the peer to the Assembly SYNCHRO Lead.
• Own the site's annual performance against the global Bürkert SYNCHRO audit in manufacturing areas,  including all six audit pillars: 5S, General/Leadership, Logistics, Management Systems/Sustainability, Standards, and Lean Workshops (i.e. Total Productive Maintenance)
• Develop and execute a structured improvement roadmap between audit cycles; ensure findings from each annual audit translate into measurable, time-bound actions.
• Drive active use of SYNCHRO tools in manufacturing, examples:

SIM12 for process deviation capture and escalation

SIM20 for workshop and improvement project management

SI01 (Machine Status Monitor) and SI04 (OEE analysis) for machine availability visibility

SI08 (Digital Machine Handbook) — lead the build-out and ongoing maintenance of digital MHBs for CNC equipment

SIM31 for standard training and onboarding content

• Lead and facilitate improvement workshops (Kaizen, 5S, TPM, VSM) in the manufacturing environment; translate workshop outputs into documented standards that stick.
• Own and maintain the manufacturing qualification matrix per SYNCHRO standards; identify training gaps and drive the qualification plan for machinists and operators.
• Ensure annual instruction plans, familiarization plans, and SFM documentation (SFM boards, team meeting cadence, Go&See schedules) are current and compliant.
• Act as the primary Huntersville contact for the global SYNCHRO team at HQ; communicate site performance, open measures, and escalation needs proactively.

Production Documentation & Standards

• Author and maintain Factory Standards (FSTs), work instructions, BOPs, control plans, and process flow documentation for all manufacturing processes.
• Ensure SAP routing data (CM25 / Fiori) accurately reflects current process times, sequences, and resource assignments — own the routing master data for manufacturing.
• Build and maintain digital machine handbooks in SI08 for production-critical CNC equipment; ensure maintenance tasks, log entries, and inspection records are current.
• Establish structured filing practices on the production drive (P:\) per SYNCHRO Office standard; lead the cleanup and standardization of legacy documentation.
• Drive poka-yoke implementation across machining setups and inspection processes — make errors impossible before they become defects.

New Manufacturing Areas, Growth & Support

• Support process development in welding operations, with a particular growth path toward ASME BPE orbital GTAW welding as the program scales. CNC machining and turning expertise is the priority; welding process knowledge is a valued plus and an area for development.
• Contribute to process improvements in secondary operations (deburring, washing, inspection) as part of the full manufacturing value stream.
• Engage with intralogistics improvements (material flow, milk running, kitting) as they interface with machining cell efficiency.

REQUIREMENTS:

Education:

• Bachelor's degree in Manufacturing Engineering, Mechanical Engineering, Industrial Engineering, or a closely related technical discipline required.
• Lean Six Sigma Black Belt preferred; Green Belt with demonstrated Black Belt-level project experience considered. Certification must reflect practical application, not classroom credential.

Experience:

• 5 to 8 years of progressively responsible experience in a precision CNC machining environment — turning, milling, multi-axis machining of close-tolerance components.
• Demonstrated ownership of machining process improvement: spindle utilization, setup reduction, tooling programs, and scheduling discipline.
• Direct experience with SAP production modules — CM25 / Fiori scheduling, routing management, and capacity planning.
• Hands-on experience with tool management systems; Siemens TMGR experience is a strong differentiator.
• Experience leading Kaizen events, VSM workshops, and 5S programs in a machining or fabrication environment — not as a participant, as the leader.
• Experience with a formal production management system (Bürkert SYNCHRO+, Bosch Production System, lean factory systems) is a significant advantage.
• CAD/CAM proficiency (Siemens NX, Mastercam, or equivalent); Vericut simulation experience preferred.
• Familiarity with GD&T, precision measurement, and CMM-based inspection processes as they apply to machined components.

Skills:

• CNC machining — turning and milling technologies, multi-axis setups, fixturing, and tooling strategy
• SAP (CM25 / Fiori): scheduling, routing, capacity management
• Siemens TMGR or equivalent tool management system
• OEE measurement and analysis (SI04 or equivalent)
• Lean tools: VSM, Kaizen, 5S/6S, TPM, SMED, standard work
• Six Sigma tools: DMAIC, control charts, DOE, FMEA, root cause analysis (Ishikawa, 5-Why, A3)
• Process documentation: FSTs, BOPs, control plans, routing sheets
• SYNCHRO+ modules (or willingness to become expert rapidly): SIM12, SIM20, SI01, SI04, SI08

Leadership & Behavioral Requirements

• Practitioner mindset — you are most effective and most credible on the floor, not in conference rooms. Machinists and operators will follow you because you understand the work.
• Independent, balanced perspective — this role exists to find waste and drive improvement with objectivity. You are not beholden to the status quo; you report to the VP of Operations for a reason.
• Strong influencing skills — you have no direct authority over machinists or the CNC Manufacturing Manager, but you drive change through credibility, data, and coaching.
• Bias for ownership — open findings become your findings. You don't document problems; you close them.
• Genuine curiosity about manufacturing systems — SYNCHRO+ is not a compliance checkbox here. We expect this person to become a real expert and drive the system forward.
• Willingness to learn adjacent processes (welding, assembly interfaces, supply chain touchpoints) and grow the role over time.

Milestone

Expected Outcome

SYNCHRO Audit Performance

Manufacturing SYNCHRO AUDIT area score advances beyond 70% (2024 baseline) toward 75%+ target, with all 9 open audit measures closed or in-flight with owners and due dates.

SI04 / OEE Deployment

SI04 OEE analysis activated for primary CNC cells; baseline established and visible on SFM boards; first improvement cycle underway.

SI08 Digital MHBs

Digital machine handbooks live for all production-critical CNC equipment; maintenance tasks loaded, assigned, and tracked in system.

Spindle Time

Measurable increase in spindle utilization on primary machining cells versus baseline at hire; methodology for ongoing tracking established.

SAP Routing Integrity

All manufacturing routings in CM25/Fiori reviewed, corrected, and signed off; routing accuracy baseline documented.

Tooling Program

TMGR tool management active for at least the highest-volume machining cells; tool life data flowing and being used to reduce unplanned stoppages.

Qualification Matrix

Manufacturing qualification matrix updated to SYNCHRO standard; training gaps identified and first round of planned qualifications completed or scheduled.

Location: Huntersville, NC

In return, we offer you exciting and challenging responsibilities, diverse perspectives with a high degree of individual freedom and a corporate culture that encourages you to use it.

Curious? Then we look forward to receiving your application.