Process Engineer

Job Description

The Process Engineer is responsible for troubleshooting and optimizing manufacturing processes, while driving improvements in operational efficiency, waste reduction, process uptime, and equipment reliability. This role serves as a technical resource for all processing equipment, leads process control initiatives, and supports training and continuous improvement efforts across the site.

The Process Engineer will leverage data, process knowledge, and continuous improvement methodologies to reduce process variation, improve product quality, and enhance overall plant performance.

Essential Functions & Key Responsibilities:

Process Optimization and Troubleshooting

• Troubleshoot problems associated with manufacturing processes.
• Conduct tests and monitor the process performance throughout production.
• Identify and reduce process variation within tolerable limits using data and process controls.
• Utilize current and historical data to identify opportunities for improved efficiency and control.

Process Control and Data Utilization:

• Champion process control efficiency and continuous improvement initiatives.
• Mine and analyze production data to identify trends, risks, and opportunities.
• Drive understanding of process control methodology to minimize reactive quality checks.
• Perform process capability studies, DOE, and statistical process control analysis.

Continuous Improvement and Best Practices:

• Lead and support structured problem-solving activities (Kaizens, A3s, etc.).
• Identify high-performing assets and replicate best practices across operations.
• Evaluate and implement process improvements for production operations.

Training and Workforce Development:

• Train and educate employees on process integrity, control, and best practices.
• Develop and maintain technical training programs and troubleshooting guidelines.
• Support onboarding and ongoing training for new and existing employees.

Equipment and Reliability:

• Support equipment upgrades, retrofits, and reliability initiatives.
• Partner with Maintenance and operations to improve equipment uptime and performance.
• Manage process-related risks and highlight potential issues proactively.

Project and Capital Support:

• Determine technical and economic feasibility of process improvements and new programs.
• Develop capital estimates for new products or equipment investments.

Safety and Compliance:

• Perform all work in accordance with established OSHA, EPA, and Safety Regulations.
• Participate in safety programs and reinforce compliance standards.
• Support a strong safety culture and Human Performance Initiatives.

Additional Responsibilities:

• Miscellaneous duties as directed by leadership.

Candidate Qualifications:

• B.S. degree in Engineering – preferably with concentration in plastics/material science, or, in the absence of a plastics degree a minimum of 5 years engineering experience in extrusion, thermoforming processes or plastics processes.
• Strong skillset in sheet extrusion and inline thermoforming.
• Working knowledge of statistical process control, design of experiments and quality systems.
• Background in continuous improvement process and principles – 5-10 years of prior experience participating in and preferably leading focused improvement teams is a must.
• Supervisory experience required – directing work, coaching, managing performance and development;
  Ability to coach and train at all levels in the organization.
• Experience working within a team environment, and experience in motivating, and leading current and new employees.
• Adherence and consistent compliance to all food/BRCGS standards and regulations.
• Normal dexterity & weight-lifting requirements (requires extensive walking, bending, reaching, pushing, pulling, climbing and lifting to 30 pounds).
• Work environment:
  This position will spend approximately 80% of the time in a production floor environment of a manufacturing plant. During time spent in the manufacturing plant floor, this position is subject to moderate noise levels, high and low temperatures and other standard elements of a manufacturing environment.