Process Engineer

Process Engineer

Illinois Tool Works Inc. (ITW) is a Fortune 200 global manufacturing leader, founded in 1912, delivering specialized products and innovative solutions across diverse industries. With over $15.9 billion in revenue (2024), ITW operates with a decentralized business model focused on continuous improvement, operational excellence, and strong talent development across its global footprint.

ITW Specialty Films manufactures and markets specialized coated and metallized films used in Secure , Medical Specialty Bags, Financial Cards, Laminations, and Holographic applications. With multiple manufacturing facilities in the US, UK, and Germany, the division leverages core competencies in films, foils, holography, and laminates to meet complex customer needs.

The Process Engineer strengthens process capability and throughput across film manufacturing operations (e.g., formulation/mixing, coating, embossing and slitting/finishing), with a focus on safety, quality, yield, and cost. You'll design and refine standard operating conditions/process optimizations built upon consistent statistical data analysis for continuous improvement projects and new product/process introductions. The role partners closely with Production, Quality, Maintenance, and R&D to implement robust controls (PFMEA, Control Plans, Process Flows) and deliver measurable OEE and scrap improvements.

This position will be based in our Newburyport, MA plant but will also support the team in our Bloomfield, CT facility, with an expectation of about 30% travel to support the needs of both plants.

Essential Duties And Responsibilities

Process & Technical Excellence

• Own setup, centerlining, and optimization for film coating/embossing, and converting/winding; define and maintain standard operating conditions and process windows.
• Create/maintain PFMEAs, Control Plans, Process Flows, and operation sheets; ensure line documentation and change control are current and effective.
• Apply SPC/DOE/CPK and structured troubleshooting to stabilize gauge/thickness, adhesion, optics, roll build, and winding performance; reduce variability and scrap.
• Lead equipment capability studies and improvements to dies/air rings/web handling/coating heads, including line condition tracking and centerline management.

Continuous Improvement & Data Analytics

• Analyze OEE, downtime, scrap, and material variance; prioritize and execute Lean projects that improve yield, throughput, and cost.
• Prepare dashboards/metrics and present findings to leadership; standardize gains through SOPs, visual controls, and layered audits.
• Support capital justifications with data-driven ROI for tooling, web handling, coating/lamination, winding, and automation enhancements.

New Product / Material Scale-Up & Change Management

• Plan and run structured line trials for new film structures, coatings, laminations, and resin/material changes; capture learnings into standard conditions.
• Collaborate with R&D/Quality/Supply Chain to validate fitness-for-use, run DOE and capability checks, and ensure smooth ramp from pilot to production.
• Implement preventive maintenance frameworks with Maintenance/CMMS to sustain capability and reduce chronic losses on critical assets.

Cross-Functional Leadership & Operational Support

• Be a floor-forward engineer; work shoulder-to-shoulder with operators and techs to train, troubleshoot, and embed best practices and centerlines.
• Partner with Quality on complaint response, root cause, and CAPA; with Supply Chain on resin/film inputs; and with all leaders to uphold safety and regulatory compliance.
• Communicate clearly at shift handoffs; ensure documentation, work notes, and action registers are current, visible, and closed out on time.
• Provide customer-back suggestions to improve quality, reduce scrap, and increase first-pass yield.

What Success Looks Like

• Stable lines with tight gauge control, improved OEE, and scrap reduction.
• Documented standard conditions and trained crews that hold the gains.
• On-time, data-backed trials/scale-ups that meet cost and quality targets.

Qualifications

The requirements listed below are representative of the knowledge, skill, and/or ability required to perform this job successfully. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions.

Required

• Bachelor's degree in Chemical, Mechanical, Industrial, Materials/Polymer Engineering (or related).
• 3+ years in manufacturing/process engineering; plastics films/PVC/coating/lamination preferred.
• Proficiency with PFMEA, Control Plans, Process Flows, SPC/DOE, and data analysis tools (e.g., Excel/BI).
• Demonstrated CI mindset (Lean/Six Sigma tools) and hands-on troubleshooting ability.

Preferred

• Experience in web coating/lamination, and converting/winding.
• Familiarity with ITW's 80/20 and decentralized operating model.

Work Environment / Physical

Manufacturing environment requiring routine line-side presence; ability to stand/climb film towers; proper use of PPE; occasional off-shift…