Process Engineer II

Process Engineer II

Location:

Lockport, IL

Mid‑Senior level, Full‑time, Management and Manufacturing

Led by the Lead Process Engineer, this position will manage Process Engineering activities improving Safety, Quality, Delivery and Cost metrics while sustaining and advancing manufacturing processes focusing on EPOX. The role involves transforming molding processes to world‑class levels through process engineering.

• Manage Process Engineers through project planning, estimating tasks, milestones and project completion.
• Lead sustainment activities related to Process Engineering, including COQ(Quality) problem solving, failure analysis, and fatigue testing for molded products.
• Create sustainable processing methods and pursue mistake‑proofing with creativity.
• Drive advancement of processing techniques to support long‑term vision of growth and cost savings; oversee research and development of new manufacturing equipment/software, processes, policies, SOPs and work instructions.
• Improve manufacturing processes through review of engineering deliverables for technical accuracy and adherence to standards and schedules.
• Support and improve JDE‑QMS or other future data collection systems for continuous business intelligence reporting and data analytics.
• Establish process controls and train personnel; set critical characteristics for monitoring variables.
• Develop and conduct process audits with Quality and molding departments.
• Hire, train, mentor engineers and support staff; maintain department quality and performance metrics, write performance reviews and resolve issues.
• Review and write reports, approve expenditures, enforce rules; recommend, plan and direct installation of new equipment; communicate and collaborate with other managers and departments; prepare and deliver manufacturing‑engineering presentations as required.
• Lead and support Tooling PM program with documentation and support operations to sustain molding processes; lead tool design improvements/changes.
• Lead formulation of epoxy polymer products to achieve target attributes and execute development from bench to production scale for new product improvements.
• Possess excellent understanding of thermoset polymers from macro‑ to micro‑scale for new product development, feasibility studies and failure analysis.
• Manage cross‑function teams and apply DES, Gage R&R trials, A/B testing, and statistical analysis for development efforts.
• Lead complex and ambiguous projects, managing scope, schedule, cost, risk, resources and change.
• Track and manage key performance metrics for project success.
• Assist Molding technology lab and drive the Molding Innovation Center to help G&W reach world‑class status.

• Bachelor's degree in Plastics/Polymer Processing or Materials; 3–5+ years experience in processing.
• Strong understanding and experience executing Design of Experiments (DOE) and A/B testing.
• Experience with liquid gelation molding and ring line dispensing systems a plus.
• Knowledge of fluid dispensing systems or centralized material delivery systems monitored by a distributed control system a plus.
• Strong understanding of polymer rheology and test methods such as DSC, TGA, goniometry, DMA and physical testing.
• Experience with failure analysis using advanced techniques.
• Computer proficiency; confident with data analysis programs.
• Strong problem‑solving skills with experience using root cause analysis techniques (8D, 5
  
  Why, PDCA, A3).
• Ability to mentor, motivate and develop less experienced colleagues.
• Examples of new product production integration and operational improvement projects.

• Six Sigma, Red X or other problem‑solving certification or experience.
• Experience working cross‑functionally with all levels of the organization.
• Polymer material rheology and flow simulation experience.
• Prior history with molding and characterizing two‑component liquid thermoset plastics, cast resin compounds and vacuum casting; silicone molding experience a plus.
• Skills and understanding of CAD, Pro‑E and polymer flow simulation software; experience running a simulation and concepts of material flow and characterization for feeding the simulation.