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Key Responsibilities and Required Skills for a Process Planner

💰 $65,000 - $115,000

EngineeringManufacturingOperationsSupply Chain

🎯 Role Definition

The Process Planner is the strategic backbone of the manufacturing floor, serving as the critical link between engineering design and production reality. This role is responsible for meticulously designing, documenting, and implementing the most efficient and cost-effective methods to produce high-quality goods. A Process Planner meticulously analyzes every step of the production journey, from raw material to finished product, ensuring that processes are robust, repeatable, and aligned with a culture of continuous improvement. They are the architects of operational excellence, translating complex engineering blueprints into clear, actionable plans that empower the production team to succeed.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Manufacturing Technician or CNC Machinist
  • Junior Manufacturing Engineer or Industrial Engineer
  • CAD Drafter or Designer
  • Quality Inspector or Technician

Advancement To:

  • Senior Process Planner or Principal Manufacturing Engineer
  • Manufacturing Engineering Manager or Operations Manager
  • Continuous Improvement (CI) Manager or Lean Specialist
  • Program or Project Manager

Lateral Moves:

  • Quality Engineer
  • Supply Chain Planner or Analyst
  • Design Engineer

Core Responsibilities

Primary Functions

  • Develop, write, and maintain detailed, clear, and comprehensive manufacturing work instructions, process sheets, and standard operating procedures (SOPs) to ensure consistent and high-quality production.
  • Analyze engineering drawings, 3D models, specifications, and parts lists to determine the optimal manufacturing methods, assembly sequences, and tooling requirements.
  • Create and meticulously manage manufacturing Bills of Materials (MBOMs) and production process routings within the company's ERP/MRP system to ensure data accuracy for planning and costing.
  • Design, justify, specify, and procure necessary tooling, jigs, fixtures, and equipment to support efficient and ergonomic production processes.
  • Lead and actively participate in Process Failure Mode and Effects Analysis (PFMEA) workshops to proactively identify and mitigate potential risks within the manufacturing process.
  • Estimate production cycle times, labor requirements, and associated costs to provide critical data for product costing, management decisions, and new business quotations.
  • Drive and champion continuous improvement initiatives using Lean Manufacturing principles (Kaizen, 5S, VSM) to enhance product quality, reduce operational costs, and improve production flow.
  • Act as a key liaison with the Design Engineering department to provide critical Design for Manufacturability (DFM) and Design for Assembly (DFA) feedback early in the product development lifecycle.
  • Serve as the primary technical resource for the production floor, actively troubleshooting and resolving manufacturing process issues to minimize downtime and maintain output.
  • Plan, execute, and document process validation and capability studies (e.g., Cpk, Ppk) to ensure that manufacturing processes are stable, repeatable, and meet all quality specifications.
  • Manage the seamless introduction of new products (NPI) into the manufacturing environment, coordinating all cross-functional activities from initial pilot runs to full-scale production launch.
  • Review, assess, and implement Engineering Change Orders (ECOs), analyzing their impact on existing manufacturing processes, tooling, documentation, and inventory.
  • Develop and optimize plant, cell, and workstation layouts to improve material flow, eliminate waste, and enhance ergonomic and safety conditions for the production team.
  • Conduct formal and informal training for production personnel on new or revised manufacturing processes, equipment, and procedures to ensure proper execution and adherence to standards.
  • Investigate and support the disposition of non-conforming materials and products, leading root cause analysis and implementing robust corrective and preventive actions (CAPAs).
  • Evaluate, research, and recommend new manufacturing technologies, automation solutions, and software systems to advance production capabilities and maintain a competitive edge.
  • Maintain a highly organized and compliant system of process documentation in accordance with company policies and relevant industry standards (e.g., ISO 9001, AS9100, IATF 16949).
  • Interface directly with suppliers and external vendors to clarify raw material requirements, component specifications, and to qualify outsourced manufacturing processes.
  • Prepare and deliver compelling technical reports, project status updates, and business case presentations to management and cross-functional project teams.
  • Support the Sales and Quoting teams by providing detailed labor, tooling, and material cost estimates for new and prospective business opportunities.
  • Ensure all manufacturing processes and work environments are designed and maintained in strict compliance with all relevant Environmental, Health, and Safety (EHS) regulations.

Secondary Functions

  • Support ad-hoc data requests and perform exploratory data analysis to uncover trends and opportunities for process optimization.
  • Contribute to the development and evolution of the organization's overarching manufacturing technology and data strategy roadmap.
  • Collaborate with various business units to translate their operational needs and challenges into actionable engineering requirements and projects.
  • Participate actively in sprint planning, daily stand-ups, and other agile ceremonies within the broader engineering and operations teams.
  • Mentor junior engineers, technicians, and interns, sharing knowledge and best practices related to process planning and manufacturing excellence.

Required Skills & Competencies

Hard Skills (Technical)

  • CAD/CAM Software Proficiency: Expertise in interpreting and working with 2D/3D models using software like SolidWorks, CATIA, Siemens NX, or AutoCAD.
  • ERP/MRP System Mastery: Deep hands-on experience with enterprise systems such as SAP, Oracle, Infor, or Epicor for managing BOMs, routings, and production orders.
  • Geometric Dimensioning & Tolerancing (GD&T): Strong ability to read, interpret, and apply GD&T from engineering drawings to ensure part conformity.
  • Lean Manufacturing Principles: Proven application of Lean tools and methodologies, including Value Stream Mapping (VSM), 5S, Kaizen, Kanban, and Poka-Yoke.
  • Process Risk Assessment (PFMEA): Demonstrated experience in leading or contributing to Process Failure Mode and Effects Analysis to mitigate production risks.
  • Technical Documentation: Exceptional technical writing skills for creating clear, unambiguous, and user-friendly work instructions, SOPs, and reports.
  • Root Cause Analysis & Problem Solving: Proficiency in structured problem-solving methodologies like 8D, 5 Whys, and Fishbone (Ishikawa) diagrams.
  • Cost Estimation: Skill in accurately estimating labor, material, and tooling costs for manufacturing processes.
  • Manufacturing Process Knowledge: Broad understanding of a variety of manufacturing processes such as CNC machining, metal fabrication, welding, injection molding, or electronics assembly (SMT/Thru-hole).
  • Project Management: Ability to plan, execute, and manage multiple projects simultaneously, from conception to completion, while meeting deadlines and budget.

Soft Skills

  • Analytical & Critical Thinking: The ability to deconstruct complex problems, analyze data, and arrive at logical, data-driven solutions.
  • Meticulous Attention to Detail: A precise and thorough approach to all tasks, ensuring accuracy in documentation, data, and process design.
  • Collaborative Team Player: A natural ability to work effectively within and across departments, including engineering, quality, production, and supply chain.
  • Clear & Concise Communication: Excellent verbal and written communication skills, with the ability to convey complex technical information to diverse audiences.
  • Adaptability & Resilience: Thrives in a dynamic, fast-paced manufacturing environment and can pivot priorities as needed.
  • Proactive & Self-Motivated: A strong sense of ownership and the initiative to identify problems and drive improvements without constant supervision.

Education & Experience

Educational Background

Minimum Education:

  • An Associate's Degree in a technical field or a combination of a technical certification (e.g., Journeyman Machinist) and significant relevant experience.

Preferred Education:

  • A Bachelor of Science (B.S.) degree is highly preferred.

Relevant Fields of Study:

  • Manufacturing Engineering or Manufacturing Engineering Technology
  • Industrial Engineering
  • Mechanical Engineering
  • Operations Management

Experience Requirements

Typical Experience Range:

  • 3-7 years of direct experience in a process planning, manufacturing engineering, or industrial engineering role within a manufacturing environment.

Preferred:

  • Experience in a regulated industry such as aerospace (AS9100), medical device (ISO 13485), or automotive (IATF 16949) is a significant asset.
  • Demonstrable hands-on experience with New Product Introduction (NPI) processes and leading projects from the development stage into full production.
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