Process Engineer

Summary: The Process Engineer is responsible for providing engineering expertise in the areas of thermoforming process development and improvement, supports the launch of new products and continuously improves existing products and processes. Provide advanced level process troubleshooting support, process training and data analysis. Identifies areas for improvement and participates in continuous improvement activities to reduce product and process variability and improve production efficiencies.

Essential Job Functions:

  1. Provides technical expertise and project management support relating to process improvement projects for new and/or existing products
  2. Works with the manufacturing staff, as required, developing process engineering documentation, systems and auditing procedures
  3. Areas of expertise include: Applicable materials & equipment knowledge
  4. Performs manufacturing performance analysis to reduce processing costs through creative engineering and proactive procedures
  5. Performs process capability studies and root cause analysis for resolution of manufacturing problems and assists with implementation of corrective actions
  6. Coordinates with plant personnel and establishes process improvement teams for cost savings opportunities
  7. Develops and maintains SMED activities to decrease mold change over times from last good part to first good part to less than 4 hours on preheat machines and 2 hours on contact heat machines and documents accordingly
  8. Ensures all molds are running at the BOM standard cycle time or better and that any changes are documented to ensure all processing is maintained to IPC procedures
  9. Provides detailed technical guidance and training to thermoforming machine operators, Setup Mechanics and Electro-mechanical/Setup Technicians
  10. Develops and documents standard training practices
  11. Willing to work a swing shift on Tuesday or Thursday evenings, once per week for the purpose of developing the second shift technical staff and ensuring consistency of work
  12. Acts as a liaison to the Central Engineering Department for equipment RFP's and RFQ's, commissioning of new equipment, analysis relating to facility infrastructure needs and design improvements for manufacturing equipment
  13. Acts as a liaison to the R&D Department to evaluate, recommend, and implement tooling design changes in order to improve Overall Equipment Effectiveness (OEE)
  14. Maintains strong relationships with current and potential vendors to provide technical guidance in new equipment selection for new projects, equipment upgrades and troubleshooting
  15. Generates, maintains and adheres to project expense and capital budgets
  16. Maintains a neat, safe and clean environment at all times and strictly enforce this
  17. Helps support building a strong team that is cross functional across all Departments
  18. "Leads by example" and maintains a strong professional demeanor at all times and always possess a "Can do attitude"
  19. Ensures established process parameters surpass company operating efficiency standards
  20. Accurately and systematically records data used to analyze set-ups, change-overs, and processes
  21. Will perform all other duties as assigned
  22. Follows Product Safety and Quality standards
  23. Follows FDA GMP's in regards to food contact packaging as it pertains to the employee
  24. Follows and IPC product defense standards and complies with all SQF requirements
  25. Practices safe work habits and follows general safety procedures such as proper lifting and bending, ergonomics, proper use of equipment and use of personal protection equipment (PPE)
  26. Practices good housekeeping including clutter-free work area and general cleaning; follows FDA product safety standards
  27. Ensures lockout procedures are followed any time the equipment is being cleaned or maintained
  28. Ensures all safety procedures are strictly adhered to including that "Lock out and tag out" is strictly enforced and disciplined

Requirements:
  1. Must have a High School education with a minimum of 15 years progressive thermoforming experience, a two year technical degree with minimum of 10 years of progressive thermoforming experience, or a four year engineering degree, which is preferred, with a minimum of five years thermoforming experience
  2. Extrusion experience is beneficial
  3. Must be able to score an acceptable grade on the company issued processing skill-set test
  4. Continuing education as required staying abreast of new developments area of expertise
  5. Must be proficient in Microsoft Office, MRP/ERP
  6. Must be proficient in Microsoft Project software
  7. Must be able to manage multiple projects simultaneously and work under minimal supervision
  8. Must have the ability to read, analyze, and interpret common scientific and technical journals, financial reports
  9. Must have the ability to effectively present information to top management, public groups, and/or board of directors
  10. Must have the ability to comprehend and apply the principles of algebra
  11. Must be able to define problems, collect data, establish facts, and draw valid conclusions
  12. Must be able to interpret an extensive variety of technical instructions in mathematical or diagram form and deal with several abstract and concrete variables
  13. Must have a high degree of mechanical aptitude required.


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