Process Engineer

Job Description

Job Description

About Us:

Founded in 1966, Niterra North America, Inc. (formerly NGK Spark Plugs) is the world leader in technology, innovation, and world-class quality in the design of spark plugs and oxygen sensors. Today, that tradition continues as we transform our organization's portfolio, expand our core ceramic technologies, explore capabilities beyond traditional areas, and challenge ourselves to develop solutions and services that leverage technology to address social issues while contributing to a sustainable society.

Summary:

As a Process Engineer at Niterra, you will be responsible for advancing manufacturing capabilities by developing and optimizing automated systems. This role focuses on designing, testing, and debugging PLC and HMI logic, and integrating advanced technologies, such as sensors and vision systems, into existing equipment. You will lead cross-functional automation projects and continuous improvement initiatives (Kaizens) to enhance equipment efficiency and meet KPI targets. Additionally, you will provide technical support for maintenance, conduct root cause analyses to drive process improvements, and use AutoCAD and 3D printing to develop prototypes and solutions that drive operational success.

Classification: Salary, Exempt

Work Model: Hybrid

Responsibilities:

PLC Programming and Troubleshooting:

• Develop, test, and debug PLC and HMI logic to improve machine operations and automation.
• Diagnose and resolve issues related to PLC-controlled machinery, identifying failures in mechanical, pneumatic, and electrical components.
• Integrate new technologies (e.g., sensors, vision systems) into existing PLC-controlled equipment.

Maintenance and Support:

• Provide advanced maintenance assistance to production lines, collaborating with technical maintenance and engineering specialists as needed.
• Offer engineering-related advice and analysis on equipment specifications and procedures.
• Support preventive and predictive maintenance initiatives and accurately document all repairs and project modifications.
• Collaborate with engineering and maintenance teams on repairs, modifications, and upgrades, communicating new techniques to technical maintenance staff for consistency.

Project Management and Process Improvement:

• Lead or participate in cross-functional teams on automation projects, process improvements, cost-saving initiatives, and continuous improvement (Kaizen) initiatives.
• Develop and execute automation projects to enhance equipment efficiency and functionality, and oversee project scopes and timelines.
• Manage labor costs and productivity for assigned projects and monitor system performance data to recommend improvements.
• Analyze KPI data to identify new project focus areas to reduce labor costs, improve KPI targets, and meet commitments to problem-solving platforms (Quality Circles, 4DX, etc.).
• Provide detailed reports on automated system changes, including cost savings, efficiency gains, and KPI improvements from completed projects.
• Conduct detailed root cause analyses to drive process improvements and present findings to management as needed.
• Perform correlations and time studies to analyze process improvement opportunities.

Training and Collaboration:

• Train production and maintenance staff on PLC systems and automated equipment as needed.
• Support training for Engineering Specialists on 3D printers and AutoCAD or similar software as needed.
• Collaborate with vendors and contractors to troubleshoot and resolve complex automation issues.
• Develop procedures for production, technical maintenance, and engineering to establish uniformity and efficient methods for their processes and modifications as needed.

AutoCAD & 3D Printing:

• Assemble and disassemble designed prototypes or products for testing or modification.
• Fulfill 3D-printed orders for spare-part systems or other departments.
• Maintain an organized 3D printer room in accordance with 5S standards.
• Utilize the 3D printer to create spare parts or prototypes for improvement projects.
• Design AutoCAD wiring schematics and parts drawings for projects or other department requests.

Statistical Process Control (SPC):

• Utilize SPC software for administrative requests from other departments.
• Compile and analyze SPC data for production, technical maintenance, and quality departments as needed.

Compliance and Safety:

• Perform all work in accordance with quality, environmental, and regulatory procedures and guidelines.
• Provide prompt, accurate communication to the appropriate personnel as required.
• Promptly report any abnormalities to management.
• Maintain a clean and organized workspace in accordance with 5S standards.
• Perform other duties as assigned by management.
• Overtime and shift changes may be necessary.
• Adhere to all company policies and procedures as applicable.

Qualifications:

• A Bachelor's degree in Engineering (Mechanical, Electrical, Industrial, or a related field) is preferred; equivalent experience (5+ years in a related engineering role) with a High School Diploma or GED will be considered in lieu of a degree.
• Advanced experience with PLC and HMI systems, encompassing programming, troubleshooting, and maintenance (e.g., Omron, Allen-Bradley, Mitsubishi).
• Demonstrated proficiency in industrial automation techniques.
• Thorough understanding of electrical systems, wiring schematics, technical drawings, PLC ladder logic, and control system diagrams.
• Experience with electrical systems, including sensors and vision systems.
• Knowledge of Statistical Process Control (SPC) principles and their application.
• Demonstrated capability in project management.
• Proficiency in computer applications, including MS Office/Google Suite, for comprehensive reporting and data analysis.
• Effective problem-solving abilities and keen attention to detail, alongside excellent time management.
• Aptitude for managing multiple projects concurrently while meeting deadlines.
• Effective communication skills and the ability to collaborate effectively within diverse teams.
• Highly organized, diplomatic, and adaptable to a dynamic work environment.
• Able to maintain confidentiality and exhibit professionalism in high-pressure situations.
• Capacity for leading training sessions for production staff, technical maintenance personnel, and Engineering Specialists as required.
• Proficiency in crafting clear, concise reports, including root cause analysis.
• Ability to monitor and enhance quality and production processes.
• Familiarity with industrial networking protocols (Ethernet/IP, Profibus, Modbus) preferred.
• Basic experience with AutoCAD or similar 3D modeling software preferred.
• Basic experience with 3D printing plastic materials is preferred.

Physical Requirements & Work Environment:

This role requires lifting up to 50 lbs. (75 lbs. with assistance), enduring prolonged periods of sitting, standing, and repetitive motion, working in both indoor and outdoor environments, wearing required safety footwear, working flexible hours and being on call as required, and working around normal business hazards.

What We Offer:

• Comprehensive Health Benefits: Medical, dental, vision, and life insurance.
• Financial Security: Short-term and long-term disability coverage.
• Retirement Savings: 401(k) plan with a generous company match of up to 6%.
• Time Off: Generous paid time off, including vacation, sick leave, and holidays.
• Work-Life Balance: Paid maternity and paternity leave.
• And much more!

Equal Employment Opportunity Statement:

Niterra is an equal opportunity employer committed to diversity and inclusion in the workplace. We prohibit discrimination and harassment of any kind based on race, color, sex, religion, sexual orientation, national origin, disability, genetic information, pregnancy, or any other protected characteristic as outlined by federal, state, or local laws.

Notice to Staffing Firms:

Niterra does not seek or accept unsolicited resumes or CVs from recruitment agencies. We are not responsible for, and will not pay, any fees, commissions, or other payments related to unsolicited resumes or CVs, except as required by a written contract between Niterra and the recruitment agency or party requesting payment of a fee.

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