Manufacturing Process Engineer

AFC Materials Group · Lake in the Hills, IL · 1 mo ago

On-siteEngineering$100k–$120k/yrFull-time

About the role

This position serves as the key technical expert for AFC’s PTFE coating operation, where fiberglass rolled goods are coated with PTFE. This position is responsible for standardizing existing coating processes and continuously developing new processes and process improvements to deliver consistent, repeatable, and capable results. This role leads large projects, trains and develops coating operators, and deep-dives complex quality issues.

Responsibilities

Serve as the subject matter expert for the end-to-end PTFE coating process, including web handling, tension control, coating application, drying, and cure profiles.
Define, document, and maintain optimal process parameters (line speed, oven zone temperatures, coating add-on/weight, and tension) to ensure consistent, repeatable output across products, shifts, and equipment.
Design and develop coating processes for new products, applications, and substrates, translating customer and product requirements into robust, manufacturable process specifications.
Establish and maintain process control plans, capability studies, and standard operating conditions for the coating line.
Apply engineering concepts, techniques, analysis, and decision tools throughout each improvement process initiative.
Drive continuous improvement initiatives that reduce process variation, scrap, and rework while improving yield, throughput, and first-pass quality.
Research and roll out new methods, materials, and equipment designed to improve processes and reduce costs, including creating ROI for proposed solutions.
Identify areas for cost reduction and implement process efficiencies.
Utilize root cause analysis tools such as 8D, 5-Why, and fishbone to analyze, understand, and correct issues, driving corrective and preventive actions to closure.
Partner with Quality Assurance to analyze nonconformances, customer complaints, and RMAs, translating findings into permanent process improvements.
Develop and lead project teams for research and development of new processes and equipment for existing and new products.
Develop and adhere to project budgets and timelines, delivering large projects on-time and within budget.
Partner with outside sources, including equipment vendors and contractors, to deliver projects on-time and within budget.
Effectively manage time and strategically prioritize projects in line with AFC’s needs.
Create documentation to support and implement improved processes and cost reduction (e.g., SOPs, work instructions, CAD designs).
Mentor and develop coating operators on standardized methods, process controls, and best practices to build technical capability and consistency across the team.
Train, coach, and develop coating operators on standardized methods, process controls, and best practices to build technical capability and consistency across the team.
Monitor performance metrics and implement continuous improvement initiatives.
Promote a positive team environment and reward and recognize individual efforts.
Perform other duties as assigned.

Requirements

Bachelor’s degree in Engineering, or a related field.
5+ years of experience in a manufacturing, process engineering, or a related role.
Experience with plastics manufacturing, continuous manufacturing, or similar processes that are dependent on time, temperature, tension, and pressure.
PTFE, dispersion coating, or web-handling experience is a strong plus.
Strong background in project management.
Knowledge of Lean, Six Sigma, or other continuous improvement methodologies.
Strong leadership, organizational, and problem-solving skills.
Process focused.
Mechanically inclined.
Excellent communication and interpersonal abilities.
Proficient in Microsoft Office and operational management software (e.g., ERP systems).
Ability to execute tasks and projects assigned.
Ability to meet established timelines and ensure projects are completed as designed and expected.
Fork truck experience or willingness to operate machinery required.

Qualifications

Must be a leader embracing and modeling AFC’s Core Values.

Skills

Project Management
Lean and Six Sigma Methodologies
Root Cause Analysis Tools (8D, 5-Why, Fishbone)
Microsoft Office Suite
Operational Management Software (ERP Systems)
Communication and Interpersonal Abilities
Leadership and Problem-Solving Skills
Process Focus
Mechanical Aptitude

Benefits

Full benefits package including medical, dental, vision, 401(k) with company match, generous PTO, and 10 paid holidays. Additionally, AFC offers annual safety shoe and gym reimbursement, tuition reimbursement, and in-house training (AFC University), along with a $2,000 referral bonus program.

Pay

$100,000 - $120,000 annually

Schedule

1st shift

About AFC

AFC Materials Group, headquartered in Lake in the Hills, IL, is a global leader in high-temperature and non-stick composite solutions. Since 1988, we’ve partnered with OEMs, distributors, and end users to solve complex production challenges through expert coating, converting, and fabrication capabilities. For over 30 years, we've built a reputation on innovation, reliability, and a strong commitment to our people and customers. Join a team where growth, quality, and forward thinking are at the core of what we do. AFC is an Equal Opportunity Employer, including disability/vets. AFC is a Drug-free workplace.