Ward Leonard, a Fairbanks Morse Defense Company, is an industry-leading provider of electric motor, generator, control, and service solutions critical to Naval applications for more than 120 years. Located in Thomaston, Connecticut, Ward Leonard has worked hard to build a reputation as being a trusted name in powering the defense industry. This trust within the market is not possible without the continued hard work, commitment, and dedication of our team who respect the importance of what we do and the impact it has on the servicemen and women.
Mission-Driven. Honor-Bound. Fairbanks Morse Defense. What’s your calling? For the men and women of Fairbanks Morse Defense, it’s the rapid and effective support of the fleets that entrust us to design, develop, and deliver the best naval power technology on the planet. We’re one of the nation’s leading marine defense contractors because of the highly trained and dedicated teams that provide reliable power systems, parts, and aftermarket services to the U.S. Navy, Coast Guard, Military Sealift Command, and Canadian Coast Guard. When you join Fairbanks Morse Defense, you join a legacy of commitment that spans 150 years. Fairbanks Morse Defense offers competitive benefits with a wide range of training and development opportunities. Our world-class teams are dedicated to helping every individual achieve their full potential. Discover what it’s like to be a part of the Fairbanks Morse Defense team here: https://www.fairbanksmorsedefense.com/careers
Position Description
Sr Process Engineer - CNC
Purpose
This position supports the Motors Business Unit by handling manufacturing engineering tasks, including creating and maintaining bills of manufacture in the ERP system, designing and sourcing tooling, reviewing drawings for manufacturability, CNC programming, and improving internal manufacturing processes.
Key Responsibilities
Manufacturing Support
- Create and maintain bills of manufacture (engineering masters) in the Visual ERP system.
- Design tools and fixtures, working with logistics to manage in-house or external manufacturing.
- Troubleshoot shop floor issues by collaborating with manufacturing, QA, logistics, and engineering teams.
- Handle Non-Conforming Materials (NCM) from both in-house production and external suppliers.
- Specify and document manufacturing processes to ensure successful part production.
- Review Engineering Change Notices (ECNs) and update engineering masters and work orders as needed.
- Research and recommend equipment to meet production and safety requirements.
- Plan and optimize new part processes in collaboration with the CNC manufacturing team.
- Maximize machine efficiency and uptime, aiming for a 90% Overall Equipment Effectiveness (OEE). Collect and analyze machine data to identify areas for improvement.
- Use SolidWorks to create operation-level drawings and prints.
- Read and interpret blueprints using ASME Y14.5 GD&T.
- Troubleshoot and resolve manufacturing issues at both the component and assembly levels.
- Develop work instructions and support Quality Management Systems (QMS).
- Assist with estimating labor and material costs for new and existing products.
- Work with CNC and maintenance teams to troubleshoot machine issues and improve performance.
- Make program adjustments in Esprit and write programs when necessary
- Lead new product integration efforts in the machine shop
Process Development
- Develop efficient manufacturing processes, incorporating fail-safe in-process inspection methods.
- Design fixtures for both new and existing parts, ensuring optimal manufacturability.
- Create operation sheets and define Key Control Indicators (KCIs) for production processes.
- Set up and program complex jobs on 5-axis CNC machines.
- Leverage Esprit CAM software for CNC programming.
Collaboration and Communication
- Suppliers: Ensure external tooling and fixtures meet specifications and support production needs.
- Sales: Provide technical input on RFQs and customer-related inquiries.
- Engineering: Collaborate on designs, tooling, testing, and rework recommendations, particularly during new product development.
- Quality Assurance: Partner with QA to review inspection methods and external supplier processes.
- Manufacturing: Work with production teams to resolve issues related to routing, tooling, raw materials, and shop floor processes.
- Materials & Sourcing: Assist purchasing with decisions on in-house production versus external sourcing.
Continuous Improvement
- Participate in Continuous Improvement Task Teams to refine manufacturing processes.
- Apply new technologies and best practices to reduce production costs.
- Conduct time studies to optimize labor and improve productivity.
- Provide updates and communicate progress or challenges to team leaders.
Physical & Safety Requirements
- Split time between office (50%) and shop floor (50%).
- Wear required personal protective equipment (PPE), including safety glasses, when on the shop floor.
- Occasionally lift to 50 pounds and work near operating machinery.
- Travel to vendor locations for audits or process qualifications as needed.
Training & Development
- Attend relevant training to stay updated on industry trends and improve job performance.
- Assist in training new engineers to ensure smooth transitions and role progression.
Qualifications
- Extensive machining experience preferred
- Experience with CAD software, particularly SolidWorks.
- Strong understanding of machining processes and best practices.
- Familiarity with rotating machines is a plus.
- Proficiency in Microsoft Word and Excel.
- Solid understanding of engineering drawings and GD&T principles.
- Excellent communication and teamwork skills.
- Experience with ISO standards and Lean Manufacturing (Six Sigma, Kaizen, Kanban, 5S) is a bonus.
- Willingness to travel domestically
Accountability
Reports to the Motors Engineering Manager. Ensures that all work is done in accordance with internal and external customer specifications and company policy. Informs Motors Engineering team and ensures awareness of all progress and problems.
Physical & Safety Requirements
Job requires sitting at a desk doing normal office work, including phone communications and using a computer. Also involves standing and walking in an office and a manufacturing facility.
- Spends roughly 50% of time working at a desk in a normal office environment.
- Spends roughly 50% of time working on the shop floor
- Must wear eye protection and any other required personal protective equipment while on the shop floor.
- Visits vendors for process qualification and/ or audit, on an as needed basis.
Training / Cross Training / Progression
Attend job related training to support job function and production requirements. Assists in the training of new Manufacturing Engineers for this position to promote orderly progression.
Fairbanks Morse Defense offers a competitive benefits package including but not limited to, medical, dental, vision, life, and disability insurances, and 401k retirement plan with employer match. In addition, we offer paid time off, paid holidays, paid parental leave, and tuition reimbursement.
Equal Opportunity Employer/Veterans/Disabled
