Process Engineer - Plastics Blow Molding

Process Engineer - Plastics Blow Molding (Open)

Process Engineer with direct plastic blow molding & PLC programming experience required, proven ability to troubleshoot and optimize process parameters. Applies knowledge of mechanical, hydraulic, pneumatic, and electrical controls, and PLC programming to support projects for repair, upgrade, or replacement of facility equipment and controls in a plastic manufacturing environment. Conducts process optimization trials, performs troubleshooting and analysis, develops strategies to reduce product variability, waste, and operating costs.

Works closely with Plant Managers, Process Technicians, and operators, providing training, standardized processes to optimize colleague safety, product quality and cost. Works on large‑scope and complex projects, resolves problems where precedent may not exist.

Preferred location:
Alsip, Illinois; requires travel to Baytown, TX and Lavonia, GA.

• Promote improvements on the production process through Kaizen, VSM, and other lean techniques in conjunction with OPEX, with emphasis on productivity gains, labor optimization, quality, seeking new methods or technologies, and replicating them in other plants.
• Prepare equipment and controls specifications, evaluate existing equipment and controls regarding productivity, cost‑efficiency, and safety, and recommend possible improvements.
• Conduct process optimization trials, perform troubleshooting and analysis, develop strategies to reduce product variability, waste, and operating costs.
• Apply root cause analysis and analytical problem‑solving techniques to daily problems and/or misses.
• Maintain complete and accurate records of all work performed, prepare monthly quality and production reports.
• Lead training of plant operators and leaders on standard production execution to assure colleague safety, product quality, and cost.
• Create, execute, and support process‑related training materials for machine operators and maintenance teams.
• Ensure adherence to existing Standard Operating Conditions (SOC) and develop and track SOC for all major equipment with min/max ranges.
• Work collaboratively with site maintenance teams to establish a Critical Process Equipment (CPE) Program to ensure all CPE items are audited and well‑maintained.
• Work with Reliability Engineer and Quality to deploy complete VQS on each equipment, develop optimum process parameters to achieve desired quality and product certification performance requirements.
• Work with plants and develop programs to ensure optimal process parameters are maintained.
• Work with facilities to help achieve and maintain product certifications.
• Replicate lessons learned, standard practices, and increase synergies across the substrate to have all plant colleagues at the same level.
• Contribute and work together with the Product Engineer to elaborate testing, prototypes, samples, or any other effort related to the production process to make new products.
• Work with the Reliability Engineer on equipment troubleshooting, documentation, and training for maintenance colleagues.
• Work with other engineering teams, with the common purpose of building a strong technical foundation at the plants.
• Work closely with OPEX and other support functions to drive A3 continuous improvement projects.

• Bachelor’s degree (or equivalent) required.
• 5+ years of direct plastic blow molding experience with proven ability to troubleshoot and optimize process parameters.

• Strong mechanical skills, including knowledge of electrical, pneumatics, hydraulics, air compressors, chillers, and PLCs, with ability to make required adjustments.
• Able to troubleshoot machine maintenance issues as they arise.
• Demonstrated success in cycle time optimization and identifying cost savings.
• Strengths in Lean Manufacturing & Continuous Improvement.
• Strong understanding of plastics materials, manufacturing processes, and machinery operations.
• Strong attention to detail and commitment to quality assurance.
• Problem‑solving skills: capability to troubleshoot and resolve production issues.
• Good communication skills and ability to work effectively…