Process Engineer

Pay range: $95,000 – $115,000 annually. Final offers are based on skill set, experience, location, qualifications and other job-related factors.

Job Description

REHAU is seeking an experienced Process Engineer to join our manufacturing team in Cullman, Alabama. In this role, you will be responsible for optimizing extrusion processes, driving continuous improvement initiatives, and ensuring quality, safety and efficiency across operations. You’ll collaborate closely with production, QA, maintenance and R&D while also supporting new product development and equipment implementation.

This position offers the opportunity to travel both domestically and internationally, including working with our technical team internationally and key suppliers.

• Process Optimization & Troubleshooting
• Analyze and improve extrusion parameters to enhance throughput, reduce waste and maintain product specifications.
• Identify root causes of process deviations and defects; implement corrective and preventive actions.
• Quality Assurance Support
• Collaborate with QA to ensure products meet dimensional, mechanical and visual standards.
• Support SPC, capability studies and quality audits.
• New Equipment & Process Implementation
• Lead installation, commissioning and validation of new equipment, tooling and auxiliary systems.
• Develop and execute process qualification protocols and ensure smooth integration into operations.
• Conduct time/motion studies to identify inefficiencies and optimise labour/machine utilisation.
• Perform cost calculations for material, cycle times, energy and labour to support continuous improvement and investment decisions.
• Documentation & Reporting
• Maintain accurate records of process settings, trials and metrics.
• Prepare technical reports and presentations for management, audits and cross‑functional teams.
• Continuous Improvement & Technology Integration
• Lead/participate in Lean, Six Sigma and Kaizen initiatives.
• Support automation, sensors and data acquisition systems for real‑time monitoring and control.
• Training & Support
• Train operators and technicians on SOPs, troubleshooting and best practices.
• Provide technical support for daily operations and improvement projects.
• Safety & Compliance
• Ensure compliance with OSHA regulations, REHAU policies and ISO standards.
• Promote a strong culture of safety and environmental responsibility.

Technical Skills

• Strong knowledge of polymer materials and extrusion behaviour.
• Proficiency with extrusion equipment (extruders, dies, calibration tables, haul‑offs).
• Familiarity with PLC/SCADA systems and data analysis tools.
• Understanding of rheology, heat transfer and fluid dynamics.

Analytical & Problem‑Solving

• Strong troubleshooting/root cause analysis.
• Ability to interpret process data, charts and SPC/DOE results.
• Experience with FMEA and risk mitigation.

Project Management

• Ability to manage multiple projects and trials.
• Skilled in cross‑functional collaboration and communication.

Soft Skills

• Strong communication and interpersonal skills.
• Detail‑oriented, proactive and able to work independently and in teams.

• Bachelor’s Degree in Chemical Engineering, Mechanical Engineering, Polymer Science & Engineering, Materials Engineering or Industrial Engineering (with relevant experience).
• 5–10 years of professional experience in process engineering, extrusion or related manufacturing fields.

• Master’s Degree in Polymer Engineering, Process Engineering or Manufacturing Systems Engineering.
• Coursework/experience in thermoplastics, extrusion, fluid mechanics and heat transfer highly beneficial.

Technical & Industry

• Certified Manufacturing Engineer (CMfgE) – SME.
• Lean Manufacturing Certification.
• Extrusion Process Training (Polymer Center of Excellence, Penn College, SPE, etc.).

Quality & Compliance

• ISO 9001:
  Quality Management Systems.
• OSHA Safety Training.

Software & Tools

• PLC Programming & Automation Systems.
• SPC Tools.
• CAD/CAM or Simulation Software (Solid Works, Moldflow, etc.).

Salary range: $95,000 – $115,000 annually
, based on experience and qualifications.

Occasional travel required, both domestic and international
, to meet with suppliers and to collaborate with REHAU’s technical team in Germany.

Equal Opportunity Employer
This employer is required to notify all applicants of their rights pursuant to federal employment laws. For further information, please review the Know Your Rights notice from the Department of Labor.