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Process Engineer - Die Casting and Machining, provides quality and technical guidance to engineering on cross-functional R&D and Operations projects, including New Product Development, Product Support, and Value Engineering. This role combines technical expertise in supplier manufacturing processes with specialized knowledge in materials and metallurgy. The primary duty of this position is to provide supplier selection support, technical expertise, and supplier development for Milwaukee Tool's key suppliers. SPE will participate in on-site supplier process assessments/audits to assess supplier technical capabilities and provide on-site support as needed. This position will develop action plans and drive implementation to close supplier technical gaps within component manufacturing.

Duties and Responsibilities

• Plan, coordinate, and conduct supplier process audits to ensure necessary process controls are in place during supplier assessment visits or ongoing supplier management assessments.
• Implement and maintain process improvement and monitoring systems with suppliers, focusing on process controls, test laboratories, quality control, scrap reduction, efficiency, quality management, and quality systems.
• Understand supplier capabilities and communicate potential improvements to purchasing, engineering, and quality teams.
• Identify systemic supplier quality issues, driving corrective and preventative actions through data analysis, root cause methodologies, and problem resolution.
• Provide specialized expertise in metallic manufacturing processes and lead technical problem-solving initiatives.
• Communicate complex concepts related to process improvements and negotiate effectively with stakeholders to implement changes.
• Oversee the setup, operation, and troubleshooting of supplier manufacturing and testing equipment.
• Collaborate with suppliers to analyze, optimize, and validate manufacturing processes, focusing on metallic materials and special processes.
• Support the quality team in resolving critical supplier and internal materials-related issues.
• Manage the Materials Laboratory, ensuring efficient operation, maintenance, and calibration of equipment.
• Supervise and provide guidance to laboratory technicians, ensuring adherence to testing protocols, safety standards, and quality procedures.
• Generate technical reports based on failure analysis and audits, providing actionable recommendations, including corrective actions, process improvements, heat treatments, and other optimizations.
• Supervise and conduct metallurgical and materials analyses, mechanical and chemical tests, and failure studies for critical components, implementing new analytical methodologies as needed.
• Ability to negotiate effectively and communicate requirements with suppliers in a clear, respectful, and professional manner.
• Participate in research and development initiatives for new materials or processes that benefit the supply chain.

Education and Experience Requirements

Required

• Degree in Materials Engineering, Metallurgy, or a related field with a minimum of 5 years of experience as a manufacturing/process engineer or supplier quality engineer in metals and special processes.
• Solid knowledge of material analysis, corrosion, heat treatment, surface engineering and metallic manufacturing processes.
• Experience with ISO 9001, IATF 16949, VDA 6.3, and CQI audits (CQI-9 for heat treatment, CQI-11 for plating, CQI-12 for coating, and CQI-27 for casting).
• Strong analytical skills with experience in DFMEA, PFMEA, Control Plans, Process Flow Diagrams, statistical data analysis, and risk analysis.
• Experience with the Production Part Approval Process (PPAP) for metal components.
• Technical project management skills and leadership in improvement initiatives.
• Working knowledge of Quality Management Systems to support Supplier Corrective Actions (SCAR) and root cause analysis (e.g., 8D).
• Fluent in English (speaking and writing).
• Travel required up to 50-75% domestically and internationally, sometimes on short notice.

Preferred:

• Certification in ISO 9001, IATF 16949, VDA 6.3, CQI-9, CQI-11, CQI-12, and CQI-27.
• Strong background in Lean Manufacturing or Six Sigma methodologies with relevant certifications.
• Strong understanding of stress management techniques
• Strong understanding of stress management techniques

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