Sr. Electrical Process Engineer at BlueCrest

Posted in Other 14 days ago.

Location: Danbury, Connecticut

Job Description:

BlueCrest is the innovative leader in postal and parcel automation solutions. With a focus on operational efficiency, customer experience, and technology integration, BlueCrest empowers businesses to achieve success through streamlined processes and meaningful connections from data through delivery. BlueCrest is a global company with clients and team members located in 16 countries worldwide, including an expansive field service team comprised of nine-hundred specialized field service technicians. BlueCrest's manufacturing headquarters is based in Danbury, Connecticut.

Our BlueCrest culture is reflected by our core behaviors: Innovation, Collaboration, Accountability, Resourcefulness and Enthusiasm (ICARE). It is with these behaviors in mind that we approach every customer, every idea, every product, and every employee, every day. It is the essence of how we interact and work-it's how things get done at BlueCrest.


  • Active Products Engineering includes the Process Engineering Group which is focused on support of New Product Development (by providing input and documentation to aid part design/fabrication/build and enhance manufacturability & assemblability) as well as Production Buy, Build and Integration support of the Manufacturing & Supply Chain teams.


  • Responsible for contributing to a team of Process Engineers and Technicians. Utilize leading-edge and consistent processes, tools and documentation to support product research & development efforts and manufacturing teams and initiatives. Contribute as a Process Engineer and a Core Team member to drive New Product Development and Production projects and provide manufacturing process/supplier counsel, cost analysis, product structure direction and build process documentation. Lead the resolution (Root Cause Analyses and Corrective Action) of technical problems encountered during build, integration & module/system test of products. Lead the design and set-up of prototype, pilot & production build cells. Maintain lab, test/inspection/manufacturing equipment. Develop and maintain Production Test Tools.

CORE RESPONSIBILITIES (Include Budget, P&L, and People Management Responsibilities, as appropriate)

  • Utilize Knowledge, Processes and Tools needed to generate part and product analyses and build/test processes, documentation and work cells.

    • Make vs. Buy Analyses and related Product Structure.

    • Cost Analyses. Create and optimize Product Cost Models/BOMs.

    • Manufacturing & Assembly process choice and support documentation (Make vs. Buy Analyses & Process Plans).

    • Build Cell and Test Tool development. Design and Construction of ergonomic Work Cells.

    • Develop, Document and Analyze Manufacturing/Assembly Time Studies.

  • Own or Ability to Develop the personal skill set needed for product assembly, debug, evaluate/test, and performance of "root cause" failure analysis on complex electro-mechanical systems. All leading to product qualification or definition and implementation of appropriate Corrective Action plans.

  • Lead the multi-functional team development of End-of-Line Test Tools and on-going enhancements and maintenance as required by the business.

  • Mentor and/or train junior Process Engineering team members as required.


  • Support the appropriate maintenance of lab equipment/tools/areas are accomplished, and the safety of all individuals within the lab areas are maintained. Follow prescribed safety regulations.

  • Maintain work areas and equipment in a clean, functional, calibrated and orderly condition.


A Senior Process Engineer will report directly to the Manger of Process Engineering. A Senior Process Engineer will report on a dotted-line basis to Core Team Leaders for Programs to which they are assigned. A Senior Process Engineer collaborates with peers & development team members throughout the business, primarily - Engineering, Manufacturing Operations, System Integration & Test, Product Line Management, Supply Chain and Quality. A Senior Process Engineer will mentor and/or train junior Process Engineering team members as required.


  • 3 or more years of relevant experience in the field(s) of engineering, manufacturing, engineering technology, design technology or a related field.

  • Associate's degree in Electrical Engineering, Engineering Technology or comparable practical experience.

  • Contribute to a team to accomplish shared objectives in a timely fashion.

  • Communicate effectively with management, peers and junior team members to resolve challenges and stimulate innovative thinking.

  • Effectively generate, record and evaluate data. Write clear & concise reports and correspondence to summarize & share findings and conclusions.

  • Provide written, oral, or diagrammed instructions to aid in the completion of technical tasks.

  • Maintain professional conduct & positive working relationships with all peers & management.


  • 5 or more years of relevant experience in the field(s) of engineering, manufacturing, engineering technology, design technology or a related field.

  • 3 years of relevant Product Test Tool development and maintenance.

  • Bachelor's degree in Electrical Engineering, Engineering Technology.

  • Ability to use Computer-Aided Design (CAD) software (ProE/CREO - PTC is optimal) and data manipulation tools (i.e. MS Excel).

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