Position Summary:

The Process Engineer is responsible for developing, designing, optimizing, and supervising forging and die processes to produce technically sound and high-quality forged products. This role combines hands-on shop floor guidance with advanced simulation and analytical techniques to improve productivity, material flow, and mechanical properties. The engineer collaborates with cross-functional teams including Forge, Metallurgy, Quality, and Manufacturing, and ensures all activities align with safety standards and company policies.

Primary Duties & Responsibilities:

In performing functions, duties or tasks, employees are required to know and follow safe work practices, and to be aware of Company policies and procedures related to job safety, including safety rules and regulations. All functions, duties or tasks are to be carried out in an honest, ethical and professional manner, and to be performed in conformance with applicable Company policies and procedures. In the event of uncertainty or lack of knowledge of Company policies and procedures, employees are required to request clarification or explanations from superiors or authorized company representatives.

• Design and optimize forging and heat treatment processes based on alloy composition, mechanical property data, and customer specifications.
• Develop forging preform designs using CATIA V5 to maximize material yield and mechanical performance while minimizing operational risks.
• Utilize DEFORM 2D/3D and CFD software to simulate strain, thermal conditions, and heating systems for process optimization.
• Collect and analyze process, mechanical property, and customer data to refine existing designs and develop new ones.
• Provide technical guidance and instructions to shop personnel to ensure efficient and safe operations.
• Identify and implement process improvements based on real-time observations and feedback from production teams.
• Direct die designers in tool design and modifications based on operational needs and performance data.
• Participate in cost estimation, planning, and development of Standard Work documentation.
• Create technical drawings, sketches, templates, and other production aids.
• Conduct basic and advanced inspections of dies and forgings to ensure dimensional and mechanical integrity.
• Troubleshoot process failures and conduct root cause analysis to implement corrective actions.
• Supervise forging, heat treating, conditioning, and hot inspection operations (processes).
• Assist Quality Control in auditing external vendors and identifying process deviations.
• Write technical reports and internal specifications to control complex aerospace forging processes.
• Coordinate fabrication of new equipment and process enhancements to improve material flow and process efficiency.
• Develop methodologies to streamline workflows and link processes sequentially or concurrently.
• Design and implement process controls for forging and heat treatment cycles to ensure stability and repeatability.

Required Skills:

• Ability to interpret and create Engineering drawings
• Ability to interpret, analyze, and draw conclusions from complex data
• Ability to interpret technical procedures and governmental or inter-organizational regulations
• Ability to apply principles of logical or scientific thinking to a wide range of intellectual and practical problems.
• Ability to solve practical problems and deal with a variety of concrete variables in situations where only limited standardization exists.
• Ability to interpret a variety of instructions furnished in written, oral, diagram, or schedule form.
• High comfort level with ERP systems
• High level of emotional intelligence when working with a variety of different individuals, including customers, vendors/suppliers, consultants, PCC Senior management, and shop-floor employees
• A basic understanding of project financials, product/process costing, and cost analysis
• A high-level of reasoning and problem solving ability

Experience & Education

• Bachelor’s degree in Metallurgical or Mechanical Engineering required; Master’s degree preferred.
• 4–10 years of experience in forging, die design, simulation, and process engineering.
• Strong background in numeric simulation, lean manufacturing, and experimental systems design.
• A thorough understanding of manufacturing processes; including CNC technologies, forming/forging processes, conditioning/grinding processes, ERP system interactions, and metallurgical applications.
• Expertise in CATIA V5, DEFORM 2D/3D V11, and STAR-CCM CFD software.

Physical Demands

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

While performing the duties of this job, the employee is regularly required to use hands to finger, handle, or feel; reach with hands and arms; and talk or hear. The employee frequently is required to sit. The employee is occasionally required to stand; walk; climb or balance; and stoop, kneel, crouch, or crawl. The employee must occasionally lift and/or move up to 35 pounds. Specific vision abilities required by this job include close vision, color vision, and ability to adjust focus.

Work Environment

The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

While performing the duties of this job, the employee is occasionally exposed to airborne particles and vibration. The noise level in the work environment is usually moderate.

Shultz Steel LLC is an equal opportunity employer. The companys policy and practice is to provide equal employment opportunities and to assure those opportunities, without regard to age, sex (including pregnancy, childbirth, breastfeeding or related medical conditions, gender, race, color, creed, national origin, ancestry, sexual orientation including gender identity or gender expression, religion, (including religious dress and religious grooming), mental or physical disability, legally protected medical condition, genetic information, marital status, military or veteran status, reproductive decision making, or any other status protected by applicable local, state or federal anti-discrimination laws.