Apache Stainless Equipment

Process Engineer

Apache Stainless Equipment, Beaver Dam

The Process Engineer will play a pivotal role within our engineer-to-order manufacturing environment, focusing on the design, optimization, and implementation of production processes for ASME certified tanks and integrated skid systems. This individual will collaborate cross-functionally with sales, engineering, procurement, quality, and production teams to deliver custom-engineered solutions that meet rigorous safety, quality, and regulatory standards. The ideal candidate possesses a strong foundation in process engineering, deep knowledge of ASME codes, and a drive for continuous improvement in a dynamic, project-driven setting.
Key Responsibilities

Process Development & Optimization
Develop, document, and optimize manufacturing processes for the fabrication of pressure vessels, tanks, and modular skid systems in compliance with ASME standards (Section VIII, IX, etc.).
Analyze customer specifications and translate requirements into detailed process steps, work instructions, and engineering documentation.
Design efficient workflows for one-off or low-volume, high-complexity projects, minimizing lead time and costs while maximizing quality and safety.
Implement Lean Manufacturing and Six Sigma principles to reduce waste, enhance throughput, and ensure process repeatability.

Project Engineering Support
Collaborate with sales and project management to review customer RFQs, assess manufacturability, and provide technical input and cost estimates.
Participate in design reviews and risk assessments for new projects, ensuring compliance with ASME, customer, and internal standards.
Support the development of process flows, P&IDs, equipment layouts, and bill of materials.
Coordinate with drafting and design teams to ensure process requirements are accurately reflected in manufacturing drawings and documents.
Quality & Compliance
Ensure all processes comply with ASME certification requirements, including weld mapping, material traceability, inspection, and testing protocols.
Develop and maintain process documentation, including procedures, work instructions, and checklists, aligned with ASME and company quality management systems (ISO 9001, etc.).
Investigate process deviations or non-conformances, drive root cause analysis, and implement corrective/preventive actions.
Continuous Improvement
Identify opportunities for process improvement in safety, quality, cost, and delivery performance.
Lead Kaizen events, value stream mapping exercises, and cross-functional improvement initiatives.
Monitor process KPIs and develop action plans to address gaps.
Technical Training & Support
Train shop floor personnel on new or revised processes, procedures, and safety practices.
Serve as a technical resource for troubleshooting process issues, supporting fabrication, assembly, and testing teams.
Facilitate communication between engineering, production, and quality to resolve technical challenges efficiently.
Safety & Environmental Compliance
Champion a safety-first culture by developing and enforcing safe work practices and ensuring compliance with OSHA and other relevant standards.
Participate in incident investigations and lead efforts to mitigate risks and hazards in process design and operation.
Required Qualifications

Bachelor's degree in Chemical, Mechanical, Industrial Engineering, or related discipline.
3+ years of process engineering experience, preferably in engineer-to-order or custom manufacturing environments.
Demonstrated expertise with ASME Boiler and Pressure Vessel Code (especially Section VIII) and familiarity with related codes and standards.
Experience with the design, fabrication, and testing of pressure vessels, tanks, or skid-mounted systems.
Practical knowledge of welding processes, NDE techniques, and material selection for pressure equipment.
Proficiency with CAD software, process simulation tools, and ERP/MRP systems.
Strong analytical skills and proficiency in process mapping and data analysis.
Excellent verbal and written communication skills; ability to convey technical information to diverse audiences.
Demonstrated project management and organizational capabilities in a multi-project setting.
Commitment to workplace safety, quality management, and regulatory compliance.