Utility Solutions · Hickory, NC ·
Process Engineer designs and optimizes manufacturing systems for a power-industry tool manufacturer, improving production flow, safety, and efficiency while collaborating with floor teams in Hickory, NC.
Founded in 1990, Utility Solutions is a designer and manufacturer of hot-line tools and products for the electrical power industry. Our success is based on working as a team to deliver high-quality products and unsurpassed customer service. We believe that each team member contributes directly to our growth and success as a company. Come grow with us!
We are seeking a Process Engineer to join our team in Hickory, NC!
Job Summary:
The Process Engineer is responsible for leading the design, implementation, and continuous optimization of manufacturing systems across the organization. Acting as a technical Subject Matter Expert (SME), this role bridges engineering strategy with floor-level execution to ensure production meets safety, quality, delivery, and cost objectives.
This position requires a highly hands-on, proactive engineering leader who spends significant time on the production floor working directly with operators to troubleshoot real-time issues, while also driving long-term capital projects and strategic efficiency initiatives. The Process Engineer collaborates closely with CNC operations and internal manufacturing teams to support the supply chain and ensure scalable, repeatable production processes.
Job Responsibilities:
Process Design & Optimization
● Design, develop, and implement innovative manufacturing methods to improve production flow, cycle times, throughput, and capacity
● Conduct time studies and capacity analyses to support data-driven decisions ● Lead process improvement initiatives, including tooling and fixture design
● Provide hands-on equipment support and troubleshooting
● Update and maintain SOPs to reflect best practices and process changes
● Lead 5S and workplace organization initiatives
● Improve changeover processes and reduce non-value-added activities
● Support product quality control, quality assurance, and internal audits
● Implement poka-yoke and lean manufacturing principles
Technical Leadership & Mentorship
● Serve as a technical leader and Subject Matter Expert for manufacturing processes
● Provide coaching, oversight, and development for other engineers
● Collaborate cross-functionally with production and engineering teams
Advanced Troubleshooting
● Apply structured problem-solving methodologies, including true root cause analysis and 5 Whys with Preventive Actions (PA), Corrective Actions (CA), and Opportunities for Improvement (OFI)
Continuous Improvement
● Champion Lean and Six Sigma initiatives, such as Kaizen events, Value Stream Mapping, and waste reduction projects
● Drive improvements in yield, scrap reduction, and overall equipment effectiveness
New Product Introduction (NPI)
● Support the industrialization of new products from prototype and R&D stages into full-scale manufacturing
● Ensure processes are scalable, repeatable, and production-ready
● Partner with CNC and internal manufacturing teams to ensure part availability and manufacturability
Required Qualifications:
● 5+ years of progressive experience in a manufacturing environment
● Bachelor’s or Master’s degree in Mechanical, Electrical, Industrial, or Manufacturing Engineering
● Strong safety orientation. Perform all tasks safely and responsibly
● Expertise in CAD/SolidWorks for equipment, tooling, and layout design
● Experience with 3D modeling and 3D printing
● Demonstrated ability to lead process improvement and capital projects
● Proven problem-solving, analytical, and communication skills
● Ability to work effectively on the production floor and with cross-functional teams
● Willing to submit to a pre-employment drug screen and background check
● Lean Six Sigma Green Belt or Black Belt is a plus
● Electronics and controls troubleshooting experience is a plus
● Strong mechanical aptitude with hands-on equipment experience
Work Environment:
● Approximately 25% office-based work and 75% time spent on active production lines
● Up to 10% travel may be required for multi-site projects or vendor coordination
Work Hours: 8:00am-5:00pm Monday-Friday, in office.
Salary Range: $80,000-100,000 annually.