Process Engineer

Essential Duties And Responsibilities

• Lead the setup, optimization, and ongoing improvement of mixing, coating, and converting processes.
• Develop and maintain PFMEAs, Control Plans, Process Flow Diagrams, operation sheets, and other manufacturing documentation.
• Utilize structured problem-solving methodologies to identify root causes, reduce process variation, and minimize scrap.
• Conduct equipment capability assessments and drive performance improvements for mixers, mills, gravure cylinders, coating systems, and web-handling equipment.
• Analyze key performance indicators including OEE, downtime, scrap, and material variance to identify improvement opportunities.
• Support capital investment decisions by providing data-driven analysis and return-on-investment justifications.
• Plan, coordinate, and execute production trials for new film structures, coatings, inks, resins, and material changes.
• Document results and incorporate learnings into standard operating conditions.
• Partner with R&D, Quality, and Supply Chain teams to validate product performance and successfully transition products from pilot-scale development to full production.
• Support and enhance preventive maintenance programs within CMMS to maintain equipment capability and reduce recurring performance losses on critical assets.
• Maintain a strong presence on the production floor, working closely with operators and technicians.
• Lead customer complaint investigations, root cause analyses, and corrective and preventive action (CAPA) activities.
• Collaborate with cross-functional leadership to ensure adherence to safety, quality, and regulatory requirements.
• Ensure clear communication across teams by maintaining accurate documentation, action logs, work records, and timely closure of assigned initiatives.
• Audit manufacturing processes to verify compliance with quality standards.

Continuous Improvement & Data Analytics

• Develop, maintain, and communicate operational dashboards and performance metrics.
• Sustain improvements through standardized work, visual management, and layered process audits.

New Product / Material Scale-Up & Change Management

• Coordinate and execute production trials for new film structures, coatings, inks, resins, and material changes.
• Document results and incorporate learnings into standard operating conditions.
• Support and enhance preventive maintenance programs within CMMS to maintain equipment capability and reduce recurring performance losses on critical assets.

Cross-Functional Leadership & Operational Support

• Maintain a strong presence on the production floor.
• Resolve process issues and reinforce best practices and standardized operating conditions.
• Lead customer complaint investigations, root cause analyses, and corrective and preventive action (CAPA) activities.
• Collaborate with cross-functional leadership to ensure adherence to safety, quality, and regulatory requirements.
• Ensure clear communication across teams by maintaining accurate documentation, action logs, work records, and timely closure of assigned initiatives.
• Audit manufacturing processes to verify compliance with quality standards.

Qualifications

• Bachelor’s degree in Mechanical, Industrial, Materials, Chemical or a related Engineering discipline.
• 3+ years in manufacturing/process engineering.
• Experience in plastics film/PVC, ink mixing, web coating and converting preferred.
• Proven ability to develop, implement, and improve process optimization initiatives using standard operating conditions, PFMEA, Control Plans, and change management methodologies.
• Demonstrated CI mindset with the ability to apply Lean/Six Sigma methodologies, root cause analysis, and hands-on troubleshooting to solve problems and drive continuous process improvement.
• Strong ability to manage priorities, solve problems, and drive results.
• Working knowledge of CMMS-driven PM systems and manufacturing equipment reliability practices preferred.
• Skilled in collaborating across teams and influencing outcomes without direct authority.