Process Engineer

Summary

Provides and maintains the integrity of all manufacturing processes including machines, ancillary equipment, and material handling to ensure consistent achievement of required standards of quality, output, product cost, and operating cost.

Essential Duties and Responsibilities

• Establishes optimum injection molding process for existing high cavitation molds, alternate materials and new tooling, which utilizes hot runner technology, unscrewing cores, and typically engineering resins such as nylon.
• Improves the utilization of production equipment and resources by prioritizing and addressing areas of deficiency in operations and by improving processing, troubleshooting, and problem-solving abilities.
• Develops, documents and improves manufacturing processes and improves saleable production yield by analyzing product and manufacturing methods, establishing and documenting production standards and procedures, monitoring deviations and causes, and recommending corrective actions.
• Maintains standards library for off shift reference. Documents events which have obstructed production from achieving performance to parameters/schedule. Interacts with Supervisors on all shifts to keep them informed of any problems, etc. Submits recommendations to Management as required.
• Develops systems and documentation for process control and improvement in all aspects of production.
• Improves manufacturing methods and develops procedures including Molding process, production logistics (material handling), readiness of tooling and molds, set-up reductions, minimization of operator-influenced variability, and improvement of quality. Participates as required to achieve desired results.
• Identifies, through existing data and information, deficiencies in our production operations and assumes the role of project leader to implement solutions to those deficiencies.
• Establishes, documents, and manages the process for standard process sheets which include all equipment needed, steps required, and specifications necessary, to be used for set-ups, measurement, and plant reporting.
• Researches and identifies root causes of molding non-conformances and implements solutions for their immediate and long-term elimination through participation in the corrective action process.
• Develops training plans and materials and conducts training sessions for manufacturing and tooling personnel on department procedures, methods and standards.
• Troubleshoots and assists in resolving tooling or process related issues at request of Manager, Tooling Manager, or Engineering. May be involved with the design of molds, jigs, fixtures, mechanisms and special tooling as necessary.
• Manages the execution of Engineering prototypes and sample runs in a timely manner by coordinating requirements from Engineering, Tooling, Planning and Production and ensures adequate resources are available to minimize non-productive machine time.
• Reviews product design for compliance with engineering principles, company standards, manufacturability and cost effectiveness and provides input on new designs to meet same.
• Identifies needs and provides justification for equipment or facility replacements and upgrades resulting in quality, process, or efficiency improvements.
• Meets quality and production requirements by coordinating, monitoring and controlling the use of molding machine capacity while holding excess scrap to a minimum.
• Recommends measures to improve production methods, equipment performance and quality of product.
• Improves the utilization of production equipment and resources by prioritizing and addressing areas of deficiency in operations and by improving processing, troubleshooting, and problem-solving abilities.
• Develops improved manufacturing methods, layouts, equipment and techniques and submits recommendations for approval as required by Management.
• Ensures compliance with applicable laws and regulations issued by OSHA, EPA and other federal, state and local regulatory agencies.
• Participates in all Tooling Design Review meetings as the Operations Representative.
• Responsible for starting up and initial processing of all new molds and new products to establish process parameters/standards.
• Prepares product and process reports by collecting, analyzing and summarizing information and trends.
• Maintains reference of methods and procedures by filing documents, manuals and instructions.
• Continuously improves the quality and cost-effectiveness of the area within his/her control.
• Other duties may be assigned.

Qualification Requirements

The requirements listed below are representative of the knowledge, skill, and/or ability required.

Education and/or Experience

Bachelor's degree (Plastics or Mechanical Engineering preferred) or equivalent and two plus years related experience and/or training; or equivalent combination of education and experience.

Language Skills

Ability to read, analyze, and interpret general business periodicals, professional journals, technical procedures, or governmental regulations. Ability to write reports, business correspondence, and procedure manuals. Ability to effectively present information and respond to questions from groups of managers, clients, customers, and employees.

Reasoning Ability

Ability to define problems, collect data, establish facts, and draw valid conclusions. Ability to interpret an extensive variety of technical instructions and deal with several abstract and concrete variables.

Physical Demands

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

While performing the duties of this job, the employee is regularly required to talk and hear. The employee frequently is required to stand; walk; sit; use hands to finger, handle, or feel; and reach with hands and arms. The employee is occasionally required to climb or balance and stoop, kneel, crouch, or crawl. Specific vision abilities required by this job include close vision.

Work Environment

The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

While performing the duties of this job, the employee is usually exposed to moving mechanical parts. The noise level in the work environment is usually loud.

Employee is required to follow all safety rules and procedures including, but not limited to, using required Personal Protective Equipment (PPE). PPE for this position includes safety glasses, hearing protection and hard toed shoes. Work gloves (general cloth or nitrile chemical resistant gloves) must be used when necessary.