Process Engineer

Qualification And Process Engineer III

This role is responsible for process engineering, extensive data-driven process qualification, and manufacturing optimization within a major optical fiber cable production facility. This role supports development, characterization, validation, control, and continuous improvement of cable manufacturing processes across high-volume operations. The engineer will lead or support qualifications of new products, equipment, materials, tooling, and process changes while using analytical methods to improve process capability, yield, throughput, and overall manufacturing performance.

This position requires significant experience in optical fiber cable manufacturing and a strong background in process engineering, data analytics, statistical analysis, and process qualifications. The engineer is expected to work independently on complex technical assignments, use manufacturing and quality data to drive decisions, and collaborate across Product Engineering, Operations, Quality, Reliability, Materials, and Equipment teams to ensure robust, scalable, and well-controlled production processes.

Key Responsibilities: Process Engineering

• Provide day-to-day and strategic process engineering support for optical fiber cable manufacturing operations, including areas such as loose tube, ribbon, buffering, SZ stranding, jacketing, armoring, printing, and final cable processing, as applicable.
• Develop, optimize, and sustain manufacturing processes to improve product quality, process capability, throughput, uptime, and cost performance.
• Define and maintain process windows, operating specifications, setup targets, and reaction plans for critical cable manufacturing steps.
• Support startup, scale-up, and line readiness activities for new cable constructions and process changes in a high-volume manufacturing environment.
• Evaluate interactions between materials, equipment, tooling, and operating conditions to ensure robust process performance.

Process Qualification

• Lead or support qualification of new manufacturing processes, line modifications, equipment installations, tooling changes, alternate materials, and new product introductions.
• Develop and execute qualification plans, protocols, sample strategies, acceptance criteria, and final reports for engineering trials, process characterization, capability demonstrations, and process release.
• Apply structured qualification methods, including risk-based process validation, process capability analysis, and equipment/process readiness assessments.
• Ensure qualifications address both short-term performance and long-term production stability.
• Partner with Quality and Reliability teams to ensure qualification output aligns with product requirements, test methods, and customer or industry standards.

Data Analytics and Statistical Analysis

• Analyze large manufacturing, test, scrap, and quality datasets to identify process trends, variation drivers, chronic loss mechanisms, and improvement opportunities.
• Use statistical tools to evaluate process stability, centering, and capability, including control charts, Pareto analysis, regression, ANOVA, hypothesis testing, and capability indices.
• Support designed experiments and structured process characterization studies to determine critical process parameters and interactions.
• Develop technical data summaries, reports, and presentations to communicate findings and recommendations to engineering and operations leadership.
• Use data-driven methods to support qualification decisions, process troubleshooting, and continuous improvement initiatives.

Troubleshooting and Continuous Improvement

• Investigate process deviations, product nonconformances, startup losses, yield issues, and customer-impacting defects associated with cable manufacturing processes.
• Lead or support root cause analysis using structured problem-solving methods and statistical evidence.
• Implement corrective and preventive actions to address issues such as dimensional variation, attenuation changes after cabling, excess fiber length instability, strip force variation, extrusion defects, adhesion problems, print defects, and mechanical handling damage.
• Drive continuous improvement initiatives focused on defect reduction, process robustness, waste reduction, OEE improvement, and manufacturing consistency.
• Support standardization of best-known methods across shifts, products, and production lines.

Documentation and Manufacturing Control

• Create and maintain controlled engineering documentation, including process flow diagrams, setup sheets, work instructions, SOPs, PFMEAs, control plans, qualification records, and change documentation.
• Support formal change control and determine requalification requirements for process, equipment, tooling, and material changes.
• Ensure process documentation accurately reflects current operating practices and qualified conditions.
• Participate in audit support and provide technical evidence for internal, customer, and certification reviews.

Cross-Functional Collaboration

• Work closely with Manufacturing, Product Engineering, Materials Engineering, Quality, Reliability, Maintenance, Tooling, Automation, and Supply Chain teams to resolve technical issues and implement process improvements.
• Support new product introduction by ensuring manufacturing readiness, process capability, and qualification completeness.
• Communicate technical risks, qualification status, and process performance clearly to stakeholders.
• Mentor junior engineers, technicians, and operations personnel on process qualification and data-driven problem solving.

Experience

• Bachelor's degree in Mechanical Engineering, Chemical Engineering, Materials Science, Manufacturing Engineering, Optical Engineering, Industrial Engineering, or related technical field.
• Advanced level of data analytics utilizing JMP software.
• 5+ years of experience in process engineering, manufacturing engineering, process qualification, or validation in optical fiber cable, wire and cable, polymer extrusion, or other continuous manufacturing environments.
• Significant experience working in a major optical fiber cable operation facility or similarly complex, high-volume cable manufacturing environment.
• Strong knowledge of optical fiber cable manufacturing processes and associated product quality requirements.
• Demonstrated experience in process qualification, process characterization, and process capability improvement.
• Strong analytical and problem-solving skills with experience using manufacturing data to drive engineering decisions.
• Experience with statistical analysis tools and methods for process development, qualification, and control.
• Strong technical writing skills for protocols, reports, specifications, and controlled manufacturing documentation.
• Ability to manage multiple projects and priorities in a fast-paced production environment.
• Strong communication and cross-functional collaboration skills.

Desired Skills: Mechanical

• Direct experience with ribbon manufacturing, SZ stranding, jacketing extrusion, armoring, or high-fiber-count cable production.
• Experience with statistical software such as JMP, Minitab, or equivalent analytical platforms.
• Knowledge of Telcordia, ICEA, IEC, TIA, or customer-specific fiber optic cable qualification requirements.
• Lean Manufacturing and/or Six Sigma certification.
• Experience with MES, historian systems, automated process data collection, or manufacturing dashboards.
• Background in measurement systems analysis, DOE, SPC, and advanced process control.

Education

• Bachelor's degree in Mechanical Engineering, Chemical Engineering, Materials Science, Manufacturing Engineering, Optical Engineering, Industrial Engineering, or related technical field.
• Master's or doctorate degree in Engineering, Materials Science, Data Analytics, or related field.