Lead Process Engineer

Our client is seeking a Process Engineer to join their team and be part of a major expansion featuring new thermoforming technology, advanced automation, and a brand-new production environment. As a Process Engineer, you'll have the opportunity to apply your engineering expertise to help launch, optimize, and continuously improve processes from raw materials through finished products.

You'll work closely with production, maintenance, engineering, and other cross-functional teams to solve complex challenges, improve equipment and processes, and help establish the systems and standards that will support a successful operation from day one.

Responsibilities

• Apply engineering knowledge and skills to moderately complex projects focused on creating and improving process control systems and procedures
• Manage, prioritize, and complete projects or programs of moderate to large size, scope, and duration
• Support the startup, testing, and implementation of new equipment, processes, and engineering solutions
• Troubleshoot, analyze, identify, evaluate, propose, implement, and document solutions to process and equipment challenges
• Lead process failure discussions, audits, and investigations to identify root causes and drive consistent solutions
• Develop and document Standard Operating Procedures (SOPs), Process Control Plans, and Process Reaction Plans
• Perform feasibility studies related to fabrication, assembly, machining, and processing
• Assist technicians with the assembly and disassembly of process equipment and components to diagnose and resolve issues
• Create test parameters and participate in testing, data analysis, and implementation of new processes and equipment
• Collaborate with production and other departments to gather information, develop solutions, improve processes, and enhance product performance
• Coordinate project work with engineers, technicians, designers, and drafters
• Establish continuous improvement plans focused on safety, quality, efficiency, production, and service
• Help ensure processes meet company standards, GMP requirements, and applicable laws and regulations
• Deliver measurable improvements in equipment reliability, process capability, quality, efficiency, and production performance

Competencies

• Strong analytical and problem-solving skills with the ability to evaluate complex manufacturing challenges
• Ability to use logic and reasoning to identify strengths and weaknesses of alternative solutions and approaches
• Strong understanding of manufacturing processes, production equipment, raw materials, and quality control
• Ability to translate engineering concepts into practical manufacturing solutions
• Strong project management and organizational skills with the ability to prioritize multiple projects and deadlines
• Ability to work independently with minimal supervision while collaborating effectively with cross-functional teams
• Strong verbal and written communication skills with the ability to explain technical information clearly
• Commitment to safety, quality, GMP, and continuous improvement
• Comfortable working in a fast-paced environment where processes and equipment are continually evolving

Requirements

• Bachelor's degree with an emphasis in engineering or related field of study and three (3) years of related engineering experience or Associate's degree and nine (9) years of related engineering experience
• Experience analyzing production equipment, processes, and materials and solving complex issues
• Knowledge of statistical and quality methodologies including Statistical Process Control (SPC), Statistical Quality Control (SQC), 5S, 8D, Failure Mode and Effects Analysis (FMEA), Root Cause Analysis, Gage Repeatability and Reproducibility (Gage R&R), and Design of Experiments (DOE)
• Ability to develop and manage Process Control Plans and Process Reaction Plans
• Experience with thermoforming, injection molding, printing, and/or paper manufacturing equipment and processes
• Knowledge of engineering principles, techniques, procedures, and equipment used in product design and manufacturing
• Knowledge of mathematics, statistics, and their applications in engineering and manufacturing
• Knowledge of design techniques, tools, and principles used in the development of technical plans, blueprints, drawings, and models
• Understanding of raw materials, production processes, quality control, costs, and other factors that impact effective manufacturing
• Ability to successfully organize and manage projects, deadlines, and tasks in both team and independent environments
• Minimum proficiency in the English language necessary to effectively communicate safety, quality, and job-related information

Highly Desired

• Bachelor's degree in Engineering or related field
• Experience supporting new equipment installation, commissioning, startup, or manufacturing expansions
• Experience with continuous improvement initiatives in a manufacturing environment

Work Schedule and Travel

• Initial schedule will be Monday-Friday, 8:00 AM - 5:00 PM.
• As the operation ramps up and transitions to a 24/7 manufacturing environment, schedule flexibility will be required.
• Travel may be required to support training, equipment installation, startup activities, or collaboration with other facilities.