Process Engineer

Process Engineer

The Process Engineer has the responsibility to develop, analyze and implement new or modified process technologies, products, equipment, and systems under the guidance of the Plant Manager. Included are evaluation of modifications to existing products, investigate new products on existing equipment and technical assistance to manufacturing, generation and upkeep of processing specifications, defect and waste control, continuous process improvement, implementation of statistical process controls, documentation, generating of technical report and interaction with other company departments and plants. Lead and participate in both Lean Manufacturing and Six Sigma projects.

Duties and Responsibilities:

• New or Modified Product and Processes – Evaluate modified or new product and processes in manufacturing. Generating documentation, technical reports, experimental design, statistical analysis are all necessary. Determine processability, equipment and procedure required for manufacturing to assist with the evaluation and recommendation of new products for manufacturing.
• Process Equipment – Aid in new equipment startups and continuous improvement of existing equipment. Troubleshoot, generation and maintenance of process specification and general technical assistance.
• Product/ Process Improvement – Develop continuous process and product improvement through proactive defect and waste control, implementation of statistical process control, method improvements, and cost reduction using Lean Manufacturing & Six Sigma methodology.
• Production Assistance – Constant proactive interaction with manufacturing to provide technical assistance, crisis intervention, continuous process improvement, manufacturing specification, defect, and waste reduction. Includes equipment, process and raw material troubleshooting, establishment of statistical process controls.
• Require strong interaction skills with Marketing, Purchasing, Engineering, Maintenance, Production, Quality, R&D and Outside Vendors.
• Manages, plans, directs, and monitors the daily activities of Quality Technicians. Ensures personnel are trained to perform standard work. Responsible for quality assurance ensuring both results and associated documentation are maintained. Assist as point of contact for third-party quality control organizations for quarterly audits.

Required Skills/Abilities/Knowledge:

• Detailed knowledge of production equipment used to manufacture PolyIso is preferred.
• Basic knowledge of ISO and the process related interaction of raw material in the process
• Experimental design, six-sigma, lean manufacturing, and statistical process control
• Knowledge of Quality System and Manufacturing Specs
• Knowledge of other plant functions as well as other organizational functions
• Project Leadership
• Understand fundamentals of coaching, counseling, and feedback
• Knowledge of company policies and practices
• Use of PC and associated software including SAP, Minitab, SPC, Wonderware/Trend, and RFGen software
• Communication skills – oral and written. Includes projects and trial reports
• Interpersonal skills
• Budgeting skills

Competencies:

• Teamwork
• Managing Change
• Continuous Improvement
• Customer Focus
• Continuous Learning
• Drive for Results
• Leading People
• Developing People

Education and Experience:

• Education: BS in Engineering Preference Chemical from an accredited school.
• Equivalency: BS in Chemistry with 3+ years of process technical specialist
• Certification: Lean Six Sigma Black Belt
• Experience: 3+ years of process technical specialist (Preferred)
• Equivalency: Three to Five (3-5) supervisory/management experience, with at least three (3) years in manufacturing specifically.

Equipment Used:

• This position uses the following equipment in the course of the job duties: phone, radio, computer, copier, and printer, and at times will work with the chemical mixing/metering skids, web conveying equipment, laminators, robotic stacking equipment, and automatic cutting machines amongst other process equipment.

Working Conditions:

• Work Environment – Some of this employee's time will be spent in an environmentally controlled office. The remainder will be spent on the production floor, which can be hot and noisy.
• Time Worked – Typically Monday- Friday; However, days may extend as production needs dictate, 8:00 am- 5:00 pm; However, hours may extend in either direction as required.

Travel Requirement

• Less than 10% percentage of travel time expected for this position, travel will be primarily for trainings and to work in cross functional teams.

Personal Protective Equipment (PPE) Used:

• While working on the production floor, eye and hearing protection is required at all times. Other forms of PPE may be required as defined by management.