Senior Process Engineer

Description Position Overview The Sr. Process Engineer will lead the Process Engineering function while remaining heavily involved in day-to-day manufacturing engineering activities. This person will oversee process development, CNC programming, tooling specifications, gear metrology analysis, quoting support, continuous improvement initiatives, and engineering documentation. They will also provide leadership and guidance to the engineering team. Key Responsibilities Lead, mentor, and support a team of Process Engineers. Review and approve process plans, routings, tooling packages, and technical documentation. Develop and optimize manufacturing processes for precision gear production. Create CNC programs and tooling specifications for gear hobbing, shaping, and grinding operations. Analyze gear metrology results and drive corrective actions and process improvements. Coordinate with Production, Quality, and Supply Chain to resolve manufacturing issues. Support quoting activities for new and existing business opportunities. Maintain PFMEAs, Control Plans, work instructions, and SPC documentation. Ensure compliance with AGMA, ISO 9001, AS9100, and customer-specific requirements. Lead continuous improvement initiatives focused on throughput, scrap reduction, tooling life, and overall manufacturing efficiency. Support capital equipment selection, installation, and validation projects. Bachelor's Degree in Mechanical Engineering or equivalent experience. Previous experience as a Gear Process Engineer. Strong knowledge of gear manufacturing processes, including gear cutting, hobbing, shaping, grinding, and heat-treat effects. Experience with CNC programming. Strong understanding of GD&T and gear inspection/metrology. Proven process improvement and troubleshooting experience within a manufacturing environment. Strong communication, leadership, analytical, and problem-solving skills. Previous quoting experience is preferred. Must be able to meet ITAR requirements. Additional Intake Notes Reports to: Mete (Quality & Engineering Manager) Will be the lead engineer and primary technical resource for the engineering team. Position opened due to the retirement of a former Quality & Engineering leader. Direct Placement preferred (open to CTH if necessary). Salary target: $100,000 - $130,000 Schedule: Monday-Friday, First Shift, 7:00 AM - 3:30 PM No travel required. Personal history check required. Panel 5 drug screen required. Must be authorized to work in the U.S. Hiring process consists of an in-person interview with the hiring manager, followed by an introduction to the CEO. Client would like to move quickly and fill the position ASAP. Ideal Candidate We're looking for someone who combines hands-on gear manufacturing expertise with leadership capabilities. Candidates coming from precision machining, gearing, aerospace, defense, heavy industrial, or highly regulated manufacturing environments should be strong fits, particularly if they've had responsibility for process development, CNC programming, gear inspection, and engineering team leadership. Skills Process engineering, Manufacturing process, itar, cnc programs, gd&t, heat treat, root cause failure analysis, process improvement, spc, pfmea, control plans, iso 9001, quoting, leadership communication, supervisory skills, lean manufacturing, six sigma, capital equipment, tooling design, project management, machining process, cost reduction, solidworks, erp system Top Skills Details Process engineering,Manufacturing process,itar,cnc programs,gd&t,heat treat,root cause failure analysis,process improvement,spc,pfmea,control plans,iso 9001 Additional Skills & Qualifications Prepare gear designs for production. Prepare quotes on new and existing business. Evaluate and improve on processes in manufacturing systems. Maintain reliable and safe manufacturing systems while improving production rates, efficiencies, yields, costs and changeovers. Improve process capability and production volume while maintaining and improving quality standards. Develop and implement systems that optimize all phases of production process. Provide suggestions during incident investigations. Advise on corrective actions. Work with equipment designers and manufacturing officers to develop a cost-effective and working production process. Ensure projects are completed on time. Ensure financial budgets are followed. Research and purchase new manufacturing technology. Reliance Gear is a Custom Contract Manufacturer meaning they do not have their own product. They receive designs from their customers and make the parts. MUST HAVE 2 years in a production based engineering role machining, metals or automotive experience GEAR manufacturer would be perfect Experience Level Intermediate Level
Job Type & Location
This is a Permanent position based out of Elmhurst, IL.
Pay and Benefits
The pay range for this position is $100000.00 - $130000.00/yr. Individual compensation offered for this position within this range will depend on many factors, including qualifications, skills, relevant experience, job knowledge, geographic location, internal equity, and other pertinent job-related factors. Not specified in the job description. Additional information to be gathered during follow-up discussions with the hiring team.
Job Type & Location
This is a Permanent position based out of Elmhurst, IL.
Application Deadline
This position is anticipated to close on Nov 6, 2026.
Workplace Type
This is a fully onsite position in Elmhurst,IL. 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 20,000 consultants and 5,000 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500. We are proud to be an Engineering News-Record (ENR) Top 500 Design Firm for our engineering design services and a ClearlyRated Best of Staffing® winner for both client and talent service.

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.

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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
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Use of Artificial Intelligence (AI):
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