Manufacturing Process Engineer

Manufacturing Process Engineer – Gear Machining

This role supports manufacturing process engineering for gear machining operations in a high-volume powertrain facility. You will drive continuous improvement in safety, quality, and productivity by applying engineering principles and analytical techniques to develop, optimize, and stabilize machining processes for front and rear axle components. The position is highly hands-on and floor-focused, offering direct involvement in new process development, launch support, and ongoing process capability improvements for flagship vehicle programs.

Responsibilities

• Support manufacturing process engineering activities for gear machining operations, ensuring stable, capable, and efficient processes.
• Drive continuous improvement in safety, quality, and productivity within the gear machining area using structured methodologies and data-driven decision-making.
• Apply engineering principles and analytical techniques to establish, validate, and continuously improve manufacturing processes and products.
• Lead the development of interim and permanent corrective actions to resolve quality issues using 8D methodology and structured problem-solving tools.
• Lead and conduct process audits to ensure process discipline aligns with powertrain operations guidelines and internal standards.
• Conduct job ergonomic evaluations, identify risks, and implement corrective actions to improve workplace safety and ergonomics.
• Analyze carrier inventory issues and root causes, and develop mapping and corrective actions to reduce carrier rejects and improve material flow.
• Create detailed process documentation, including process sheets and instruction sheets, to support consistent quality methods and standardized work.
• Deliver capable machining processes and tools for gear machining operations, including setup optimization, process validation, and capability improvement.
• Take a lead role in resolving machining-related concerns on the shop floor, including troubleshooting CNC operations, tooling issues, and process variability.
• Lead variability reduction initiatives and implement lean manufacturing best practices to improve throughput, quality, and cost performance.
• Ensure compliance with plant, corporate, governmental, and environmental standards in all process engineering activities.
• Support ISO compliance by participating in internal ISO audits and implementing actions to maintain and improve certification readiness.
• Identify throughput constraints in gear machining and related operations, perform root cause analysis, and drive improvements to achieve rate-of-climb and production targets.
• Collaborate closely with operators, skilled trades, maintenance, quality, and production supervision to address real-time production issues and implement sustainable solutions.
• Support new product and process launches, including new axle processes, by contributing to process development, capability studies, launch support, and post-launch stabilization.
• Utilize lean tools such as 5S, Kanban, Poka-yoke, and value stream mapping to improve flow, reduce waste, and enhance process reliability.
• Apply methodologies such as DMAIC and DMADV (DFSS), as well as TQM, Kaizen, FMEA, PPAP, and DOE, to drive systematic process improvements.
• Provide clear communication, leadership, and cross-functional coordination to ensure successful implementation of process changes and continuous improvement initiatives.

Work Environment

This is a first-shift position with standard hours of 6:00 a.m. to 2:30 p.m., Monday through Friday. Minimal overtime is required; when needed, it is typically worked at the end of the shift, with occasional Saturday support (approximately one Saturday every other month) and ample advance notice. The role is based in a large-scale automotive powertrain manufacturing facility focused on the production of front and rear axles for multiple vehicle platforms. The environment is fast-paced and high-volume, with a strong emphasis on safety, quality, and on-time delivery. Process engineers spend significant time on the shop floor, working directly in machining, heat treat, welding, assembly, and material handling areas. Equipment in the facility includes CNC machining centers, automated and semi-automated assembly lines, furnaces, conveyors, inspection systems, CMMs, and specialized gear inspection equipment. The work is highly collaborative, involving close interaction with hourly operators, skilled trades, maintenance, quality, and production supervision. The facility operates as a unionized environment, and engineers are expected to be comfortable working side-by-side with plant teams to solve real-time production issues, address quality concerns, improve throughput, and enhance safety. The culture suits engineers who prefer a manufacturing-centric role, value strong cross-functional collaboration, and enjoy seeing the direct impact of their work on production performance and product quality.

Job Type & Location

This is a Contract position based out of Sterling Heights, MI.

Pay and Benefits

The pay range for this position is $42.30 - $50.76/hr.

Eligibility requirements apply to some benefits and may depend on your job classification and length of employment. Benefits are subject to change and may be subject to specific elections, plan, or program terms. If eligible, the benefits available for this temporary role may include the following: • Medical, dental & vision • Critical Illness, Accident, and Hospital • 401(k) Retirement Plan – Pre-tax and Roth post-tax contributions available • Life Insurance (Voluntary Life & AD&D for the employee and dependents) • Short and long-term disability • Health Spending Account (HSA) • Transportation benefits • Employee Assistance Program • Time Off/Leave (PTO, Vacation or Sick Leave)

Workplace Type

This is a fully onsite position in Sterling Heights, MI.

Application Deadline

This position is anticipated to close on May 29, 2026.

About Actalent

Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 30,000 consultants and more than 4,500 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500.

The company is an equal opportunity employer and will consider all applications without regard to race, sex, age, color, religion, national origin, veteran status, disability, sexual orientation, gender identity, genetic information or any characteristic protected by law.

If you would like to request a reasonable accommodation, such as the modification or adjustment of the job application process or interviewing process due to a disability, please email actalentaccommodation@actalentservices.com for other accommodation options.

San Francisco Fair Chance Ordinance: Pursuant to the San Francisco Fair Chance Ordinance, for all positions located in the city and county of San Francisco, we will consider for employment qualified applicants with arrest and conviction records.

Massachusetts Lie Detector: It is unlawful in Massachusetts to require or administer a lie detector test as a condition of employment or continued employment. An employer who violates this law shall be subject to criminal penalties and civil liability.

Use of Artificial Intelligence (AI): We may use Artificial Intelligence (AI) to support parts of our hiring process, including sourcing, screening, and evaluating candidates. AI helps assess applications and qualifications, but final decisions are made by our hiring team. By applying, you acknowledge and agree that your application may be reviewed using AI tools.