Sr. Process Engineer at BlueCrest in Danbury, Connecticut

Posted in Other 19 days ago.

Job Description:


  • Active Products Engineering includes the Process Engineering Group which is focused on support of New Product Development (by providing input and documentation to aid part design/fabrication/build and enhance manufacturability & assemblability) as well as Production Buy, Build and Integration support of the Manufacturing & Supply Chain teams.


  • Responsible for contributing to a team of Process Engineers and Technicians. Utilize leading-edge and consistent processes, tools and documentation to support product research & development efforts and manufacturing teams and initiatives. Contribute as a Process Engineer and a Core Team member to drive New Product Development and Production projects and provide manufacturing process/supplier counsel, cost analysis, product structure direction and build process documentation. Lead the resolution (Root Cause Analyses and Corrective Action) of technical problems encountered during build, integration & module/system test of products. Lead the design and set-up of prototype, pilot & production build cells. Maintain lab, test/inspection/manufacturing equipment. Develop and maintain Production Test Tools.

CORE RESPONSIBILITIES (Include Budget, P&L, and People Management Responsibilities, as appropriate)

  • Utilize Knowledge, Processes and Tools needed to generate part and product analyses and build/test processes, documentation and work cells.

    • Make vs. Buy Analyses and related Product Structure.

    • Cost Analyses. Create and optimize Product Cost Models/BOMs.

    • Manufacturing & Assembly process choice and support documentation (Make vs. Buy Analyses & Process Plans).

    • Build Cell and Test Tool development. Design and Construction of ergonomic Work Cells.

    • Develop, Document and Analyze Manufacturing/Assembly Time Studies.

  • Own or Ability to Develop the personal skill set needed for product assembly, debug, evaluate/test, and performance of "root cause" failure analysis on complex electro-mechanical systems. All leading to product qualification or definition and implementation of appropriate Corrective Action plans.

  • Lead the multi-functional team development of End-of-Line Test Tools and on-going enhancements and maintenance as required by the business.

  • Mentor and/or train junior Process Engineering team members as required.


  • Support the appropriate maintenance of lab equipment/tools/areas are accomplished, and the safety of all individuals within the lab areas are maintained. Follow prescribed safety regulations.

  • Maintain work areas and equipment in a clean, functional, calibrated and orderly condition.


A Senior Process Engineer will report directly to the Manger of Process Engineering. A Senior Process Engineer will report on a dotted-line basis to Core Team Leaders for Programs to which they are assigned. A Senior Process Engineer collaborates with peers & development team members throughout the business, primarily - Engineering, Manufacturing Operations, System Integration & Test, Product Line Management, Supply Chain and Quality. A Senior Process Engineer will mentor and/or train junior Process Engineering team members as required.


  • 3 or more years of relevant experience in the field(s) of engineering, manufacturing, engineering technology, design technology or a related field.

  • Associate's degree in Electrical Engineering, Engineering Technology or comparable practical experience.

  • Contribute to a team to accomplish shared objectives in a timely fashion.

  • Communicate effectively with management, peers and junior team members to resolve challenges and stimulate innovative thinking.

  • Effectively generate, record and evaluate data. Write clear & concise reports and correspondence to summarize & share findings and conclusions.

  • Provide written, oral, or diagrammed instructions to aid in the completion of technical tasks.

  • Maintain professional conduct & positive working relationships with all peers & management.


  • 5 or more years of relevant experience in the field(s) of engineering, manufacturing, engineering technology, design technology or a related field.

  • 3 years of relevant Product Test Tool development and maintenance.

  • Bachelor's degree in Electrical Engineering, Engineering Technology.

  • Ability to use Computer-Aided Design (CAD) software (ProE/CREO - PTC is optimal) and data manipulation tools (i.e. MS Excel).

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