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Key Responsibilities and Required Skills for CNC Process Engineer

💰 $65,000 - $95,000

ManufacturingEngineeringCNCProcess Engineering

🎯 Role Definition

The CNC Process Engineer designs, develops, and optimizes CNC manufacturing processes to reliably produce precision components while driving continuous improvement in cost, quality, and cycle time. This role is responsible for CAM and G‑code programming (Mastercam, GibbsCAM, Fusion 360, or similar), machine setup and verification (Fanuc, Heidenhain, Siemens controls), tooling and fixture design, first article validation, and cross-functional collaboration with Production, Quality, and Purchasing to deliver high-yield manufacturing processes that meet engineering print requirements and business targets.

📈 Career Progression

Typical Career Path

Entry Point From:

  • CNC Operator / CNC Machinist
  • Junior CNC Programmer / Manufacturing Technician
  • Tooling or Fixture Technician

Advancement To:

  • Senior CNC Process Engineer
  • Manufacturing / Process Engineering Manager
  • Director of Manufacturing / Plant Manager

Lateral Moves:

  • Application Engineer (CNC or tooling vendor)
  • Quality Engineer (metrology & FAI focus)
  • Tooling & Fixture Design Engineer

Core Responsibilities

Primary Functions

  • Develop and validate CNC programs for milling, turning, and mill‑turn machines using CAM systems (Mastercam, GibbsCAM, Fusion 360, Esprit), translating engineering drawings with GD&T into robust toolpaths and efficient G‑code to achieve specified tolerances and surface finishes.
  • Optimize cycle time and machining strategies by selecting appropriate toolpaths, cutting parameters, feeds and speeds, and tool change sequences while ensuring part quality and tool life targets are met.
  • Create and maintain detailed process documentation: program files, setup sheets, tooling lists, inspection plans, first article reports (FAI), and standard operating procedures (SOPs) so production teams can reproduce processes consistently.
  • Perform machine set‑up, proofing and first‑part verification on CNC mills, lathes, mill/turns and Swiss machines; verify tool offsets, work offsets, runout, and perform dial‑in and test cuts prior to production releases.
  • Lead root cause analysis and corrective actions for machining issues (scrap, rework, tool breakage, dimensional nonconformances) using structured problem solving (5Why, Fishbone) and implement permanent fixes.
  • Design and/or specify fixtures, workholding, clamps, and gauges to ensure repeatability and dimensional stability, including prototype fixtures and quick-change systems to reduce setup time.
  • Develop and maintain post‑processors and G‑code standards for Fanuc, Heidenhain, Siemens and other machine controls, working with CAM admins and suppliers to ensure correct axis mapping and canned cycle behavior.
  • Collaborate with Quality Engineering to define inspection requirements, approve measurement methods, perform capability studies (Cp/Cpk), and support FAI, PPAP or IFR processes for new and revised parts.
  • Conduct tooling selection and vendor evaluation: recommend inserts, cutters, holders, coolant strategies, and tool life monitoring approaches to minimize cost per part and maximize productivity.
  • Implement and deploy lean manufacturing and continuous improvement initiatives (Kaizen, 5S, SMED), driving measurable reductions in setup time, cycle time and scrap.
  • Simulate and verify NC code in virtual environments to detect collisions or geometry errors and perform offline programming to minimize machine downtime.
  • Perform tolerance analysis and work with design engineering to provide manufacturability feedback and propose design for manufacturability (DFM) changes that reduce machining complexity or cost.
  • Manage CNC program libraries, DNC/MDT file transfers and version control, ensuring correct program revision is in use on the shop floor and coordinating program rollouts.
  • Train and coach CNC operators and setup personnel on new processes, tooling usage, safe machine operation, and first‑part inspection criteria to raise floor competency and reduce dependency on engineering intervention.

Secondary Functions

  • Support process qualification activities for new equipment, including capability runs, documentation updates, and pilot production support to transition parts into full production.
  • Partner with purchasing and suppliers to qualify outsourced machining, tooling and special process vendors and to ensure supplier capability aligns with engineering requirements.
  • Maintain and update bills of materials (BOM) and manufacturing routing data in ERP/MRP systems and coordinate lead times and resource allocation with production planning.
  • Participate in capital equipment evaluations and ROI analyses, providing machining strategy input, expected throughput, and tooling cost estimates for automation or new machine buys.
  • Conduct periodic process audits, preventive maintenance reviews and machine capability checks to ensure long-term process stability and compliance with ISO or AS standards.
  • Drive cost reduction programs through tooling optimization, scrap reduction, cycle time compression and scrap avoidance while tracking results against defined KPIs.
  • Assist in safety risk assessments for machining operations and ensure machining fixtures, machines and processes comply with corporate safety standards and lockout/tagout procedures.
  • Provide engineering support for prototype and low-volume runs, including quick turn programming, fixture concepts and on‑the‑fly revisions to support product development timelines.

(Combined primary and secondary functions list contains 22 distinct responsibilities commonly found in CNC Process Engineer job postings.)

Required Skills & Competencies

Hard Skills (Technical)

  • CNC Programming: Expert in CAM programming and offline programming for mills, lathes and mill‑turns using Mastercam, GibbsCAM, Fusion 360, Esprit or equivalent.
  • G‑code & Post‑Processors: Strong ability to read, edit and optimize G‑code and configure post‑processors for Fanuc, Heidenhain, Siemens and other controls.
  • CAD: Proficient with CAD systems such as SolidWorks, Autodesk Inventor or AutoCAD for creating fixturing models, tooling layouts and DFM feedback.
  • GD&T & Blueprint Reading: Thorough understanding of geometric dimensioning and tolerancing to interpret and produce parts to drawing requirements.
  • Tooling & Fixturing: Knowledge of cutting tools, holders, tool life strategies, and fixture design including quick‑change and modular fixturing systems.
  • Metrology & Inspection: Familiar with CMM programming/usage, calipers, micrometers, gauges and first article inspection (FAI) methodologies.
  • SPC & Process Capability: Experience implementing statistical process control, capability studies (Cp/Cpk) and control plans.
  • Lean / Continuous Improvement: Practical application of Lean Manufacturing tools (5S, SMED, Kaizen) and Six Sigma problem-solving techniques.
  • Machine Setup & Alignment: Competence in machine setup, alignment verification, probe routines, tool offset management and machine parameter adjustments.
  • ERP / DNC Systems: Experience updating and managing manufacturing data in ERP/MRP systems and DNC file distribution for CNC machines.
  • Simulation & Verification: Ability to simulate toolpaths and use CAM verification to prevent collisions and ensure part integrity.
  • Automation & Robotics Integration: Familiarity with robot tending, pallet changers, and automation features to support higher throughput where applicable.
  • Basic Controls / PLC Awareness: Understanding of CNC control logic and basic PLC concepts for troubleshooting machine issues.
  • Materials & Machinability: Knowledge of material properties (aluminum, stainless steels, titanium, nimonic, plastics) as they affect cutting strategies and tooling choices.

Soft Skills

  • Analytical Problem Solving: Systematic root cause analysis and data‑driven decision making to resolve production issues and improve processes.
  • Communication: Clear verbal and written communication to document processes, train operators and convey technical changes to cross‑functional stakeholders.
  • Project Management: Ability to scope, plan and execute process launches or improvement projects on time and to budget.
  • Coaching & Mentoring: Hands‑on ability to train shop floor staff and transfer process ownership to production teams.
  • Collaboration: Strong cross‑functional teamwork with Design, Quality, Maintenance, Purchasing and Production to implement changes smoothly.
  • Attention to Detail: Precision focus on tolerances, inspection criteria and machining parameters to minimize rework and scrap.
  • Time Management: Prioritization skills to balance multiple programming, troubleshooting and plant support tasks effectively.
  • Continuous Improvement Mindset: Proactive search for efficiency gains, lower cost-per-part and higher first-pass yield.

Education & Experience

Educational Background

Minimum Education:

  • Associate degree or technical diploma in Machining Technology, Manufacturing Engineering Technology, or related vocational training plus relevant hands‑on CNC experience.

Preferred Education:

  • Bachelor of Science in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, or equivalent technical degree.

Relevant Fields of Study:

  • Mechanical Engineering
  • Manufacturing Engineering
  • Industrial Technology / Machinist Apprenticeship
  • Tooling & Fixture Design

Experience Requirements

Typical Experience Range: 3–8 years of progressive experience in CNC programming, process development, or manufacturing engineering with demonstrated hands-on machining experience.

Preferred: 5+ years as a CNC Process Engineer, CAM programmer, or senior machinist with exposure to multiple machine platforms (mills, lathes, mill‑turn, Swiss) and experience implementing process improvements, lean methodologies, and quality assurance practices.

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