Sr Process Engineer

Job Summary

The Sr Process Engineer reports to the Manager, Manufacturing Engineering or directly to the and 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 Responsibilities

To perform this job successfully, an individual must be able to perform each essential functions/duty satisfactorily. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.Other duties/functions may be added or assigned.

Supervisory Responsibilities

• N/A

Operations

• Provides technical expertise and project management support relating to process improvement projects for new and/or existing products.
• Works with the manufacturing staff, as required, developing process engineering documentation, systems and auditing procedures. Areas of expertise include: Applicable materials & equipment knowledge.
• Performs manufacturing performance analysis to reduce processing costs through creative engineering and proactive procedures.
• Performs process capability studiesand root cause analysis for resolution of manufacturing problems and assists with implementation of corrective actions.
• Coordinates with plant personnel and establishes process improvement teams for cost savings opportunities.
• 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.
• 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.
• Provides detailed technical guidance and training to thermoforming machine operators, Setup Mechanics and Electro-mechanical Technicians. Develops and documents standard training practices. 
• Provide full support and lead the Commercialization Process with ability to work different hours or shifts with minimum of notice.
• Ability to work flexible hours with minimum of notice.
• Provide Process support to IPC Remote Facilities, with ability to travel if necessary, with short or no notice.
• Works a swing shift, preferably once per week, for the purpose of developing the second shift technical staff and ensuring consistency of work.
• 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.
• Acts as a liaison to the R&D Department to evaluate, recommend, and implement tooling design changes in order to improve Overall Equipment Effectiveness.
• Maintains strong relationships with current and potential vendors to provide technical guidance in new equipment selection for new projects, equipment upgrades and troubleshooting.
• Generates, maintains and adheres to project expense and capital budgets.
• Maintains a neat, safe and clean environment always and strictly enforce this.
• Helps support building a strong team that is cross functional across all Departments.
• “Leads by example" and always maintains a strong professional demeanor and always possess a “Can do attitude".
• Ensures established process parameters surpass company operating efficiency standards.
• Accurately and systematically records data used to analyze set-ups, changeovers, and processes.
• Will perform other duties as assigned.

Safety

• Comply with the EH&S Policy and applicable regulatory and company EH&S rules and requirements.
• Report to supervision conditions or practices that are either unsafe or that may adversely impact the environment, to ensure prompt resolution of potential hazards.
• Attend scheduled EH&S training program.
• Actively support the organization’s efforts to meet or exceed EH&S goals and plans.
• Recommend improved EH&S practices.
• 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).
• Ensures that all fall protection procedures are strictly adhered to including but not limited to the use of harness, platform ladders, railing, lifts
• Ensures lockout procedures are followed any time the equipment is being cleaned or maintained.

Product Safety and Quality

• Follows Product Safety and Quality standards.
• Follows GMP’s regarding food contact packaging as it pertains to the employee.
• Follows IPC product defense standards and complies with all SQF requirements

Minimum Requirements (include education, experience, special skills, licenses and/or certifications required.)

The list below represents theknowledge, skill, and/or ability required to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

• Minimum of seven years relevant experience. Preferred: Four-year engineering degree, thermoforming experience is beneficial.Continuing education as required staying abreast of new developments area of expertise.Proficient in Microsoft Office, MRP/ERP.  Proficient in Microsoft Project software.Knowledge of design software, preferably SolidWorks, is a plus. Strong Mechanical/Electrical knowledge a plus, strong knowledge and understanding of SPC, CPK, DOE, FMEA as well as abilities to create data analyze graphs a plus. Must be able to manage multiple projects simultaneously and work under minimal supervision.
• Ability to read, write English speaking. The ability to read, analyze, and interpret common scientific and technical journals, financial reports. The ability to effectively present information to top management, public groups, and/or board of directors.
• Ability to comprehend and apply the principles of algebra.
• Reasoning Ability - Ability to define problems, collect data, establish facts, and draw valid conclusions. Ability to interpret an extensive variety of technical instructions in mathematical or diagram form and deal with several abstract and concrete variables. High degree of mechanical aptitude required.

Essential Physical Demands and Frequency

Thephysical 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.

Standing

Yes

Driving

N/A

Sitting

Yes

Bending

Yes

Lifting

Yes

Other

Climb/balance

Twisting

Yes

Other

Vision-close, distance, peripheral, color, depth, focus

Communication

Yes

Other

N/A