Process Engineering Supervisor (USAC)

AFL manufactures industry-leading fiber optic cable, connectivity and accessories and provides engineering and installation services for some of the largest telecom customers in the world. Our company was founded in 1984 with a single fiber optic cable and today, we manufacture thousands of products, generate an excess of $4B in revenue, and employ approximately 12,000 associates worldwide. At AFL, we recognize that our employees are our greatest asset. We hire and train each individual, investing in them to ensure success in their careers. With a commitment to professional development and growth, let us connect you to your next career opportunity.

What We Offer:

• Flexible time off policy
• 401K Company match (up to 4% - dollar for dollar)
• Professional development, training, and tuition reimbursement programs
• Excellent medical, dental, vision, and life insurance policy options
• Opportunities for career advancement with an industry leading company

General description of the role

The Process Engineering Supervisor leads the process engineering team supporting wire manufacturing at AFL's USAC facility in Duncan, SC. The role is accountable for the setup, performance, and stability of the wire drawing, aluminum cladding, and rewind processes. This includes owning machine performance metrics such as process optimization, product industrialization, safety leadership, quality and cost improvement, capital project support, managing scrap, writing safe work instructions, troubleshooting equipment, and leading structured technical problem-solving. The ideal candidate combines strong people leadership with hands-on knowledge of wire manufacturing, metal forming, and continuous improvement.

Responsibilities

• Lead and develop the team. Supervise, coach, and develop Process Engineers and Process Technicians; set priorities aligned with business objectives; support recruitment, onboarding, and cross-training; and build a culture of accountability, innovation, collaboration, and continuous improvement.
• Own manufacturing processes. Provide technical leadership for aluminum-clad steel and aluminum alloy wire manufacturing, including steel wire breakdown and finish drawing, aluminum cladding, and wire rewinding. Establish process standards, operating windows, and control plans.
• Detail setup procedures. Define and document setup procedures, process parameter sheets, tooling and die selection, and changeover standards for each line so every shift sets up equipment consistently and runs right the first time.
• Troubleshoot equipment function. Lead hands-on troubleshooting of equipment and process function on the production floor; partner with Maintenance and Operations to diagnose mechanical, electrical, and controls issues; and restore stable operation quickly.
• Write safe work instructions. Author, review, and maintain clear, safe work instructions and standard operating procedures that build in hazard controls, lockout/tagout, and PPE requirements. Train operators on them and verify they are followed on the floor.
• Own machine performance. Own line-level performance for each machine in the area, including Right First Time (RFT), First Pass Yield (FPY), uptime, and throughput. Set targets, track results by machine and product, and drive improvements in safety, quality, delivery, cost, process capability, and stability.
• Manage scrap. Own scrap tracking and reduction for the area: quantify scrap by machine, product, and cause; lead actions that reduce scrap, rework, downtime, defects, and variability; and partner with Quality on nonconforming material disposition.
• Lead technical problem-solving. Direct structured root-cause investigations, corrective and preventive actions, and resolution of chronic manufacturing issues and customer quality concerns.
• Industrialize new products and processes. Lead process development, risk assessments, qualification trials, manufacturing readiness, and specifications for new wire products and equipment. Partner with Product Engineering and Operations to transfer new products and technologies into production.
• Advance continuous improvement. Lead Lean, Six Sigma, and DMAIC projects; apply statistical methods and data analytics; establish KPIs; and monitor performance trends.
• Support quality systems. Maintain process documentation and production records; support internal and external audits; and help maintain compliance with ISO 9001 and ISO 14001 requirements.
• Execute capital projects. Support equipment specification, procurement, FAT, installation, commissioning, startup, and qualification. Lead engineering support for new lines and capacity expansions, including technical justification and ROI analysis.
• Champion safety and sustainability. Promote a safety-first culture, lead hazard assessments and mitigation, ensure engineering compliance with safety and environmental requirements, and support waste-reduction initiatives.

Qualifications

• Bachelor's degree in Mechanical, Metallurgical, Materials Science, Manufacturing, Industrial, or a related engineering discipline.
• Seven or more years of manufacturing or process engineering experience, including three or more years leading engineers or technical personnel.
• Experience in wire drawing, metal forming, aluminum extrusion or cladding, wire and cable, or a similar continuous manufacturing environment.
• Demonstrated success leading process improvement initiatives and delivering measurable manufacturing results.

Technical knowledge

• Wire drawing, drawing die design and lubrication, aluminum cladding, or related technology.
• Statistical Process Control, process capability analysis, Design of Experiments, and manufacturing data analytics.
• Root Cause Analysis, Lean Manufacturing, Six Sigma, and structured problem-solving methods.
• Industrial automation and controls fundamentals, and hands-on troubleshooting of mechanical, electrical, and PLC-controlled equipment.
• Project management, cross-functional communication, prioritization, and decision-making.

Preferred qualifications

• Lean Six Sigma Green Belt or Black Belt certification.
• Experience with aluminum-clad steel, aluminum alloy, or other bimetallic wire products, or with OPGW and overhead conductor manufacturing.
• Experience leading capital projects and commissioning manufacturing equipment.
• Knowledge of metallurgy, work hardening, annealing, and drawing process optimization.
• Experience with ERP systems, preferably Oracle.

Personal qualities

• People-focused leader. Builds capability through coaching, clear expectations, feedback, development planning, and succession planning.
• Accountable and results-oriented. Takes ownership, follows through, and connects engineering priorities to measurable business outcomes.
• Analytical problem-solver. Uses facts, data, and structured methods to make sound decisions and resolve complex manufacturing problems.
• Collaborative influencer. Works effectively across Operations, Quality, Product Engineering, suppliers, and other stakeholders without relying solely on formal authority.
• Clear communicator. Explains technical information effectively and communicates priorities, risks, and recommendations to technical and leadership audiences.
• Customer-focused. Balances safety, quality, delivery, and cost while maintaining strong internal and external customer focus.
• Improvement-minded. Challenges the status quo, encourages innovation, and creates an environment where teams learn and improve continuously.
• Safety and environmental steward. Models safe behavior and integrates risk reduction and sustainability into engineering decisions.