Lead Process Engineer

Process Engineer, Lead

The Process Engineer Lead will lead a team of process engineers by being accountable and responsible for the technical ownership of the production process and ensure junior process engineers are trained. The lead will be responsible for the complete process control, technical oversight of a continuous production process, to ensure maximum up-time, with highest efficiency, excellent quality, and provide mentorship and technical guidance to other process engineers.

Additionally, the engineer will lead multiply departmental efforts with new product development and production integration. This is a hands-on process engineering role, and will require ingenuity, flexibility and problem-solving capabilities using RCCA, Lean Six Sigma or any other technical tools and data to solve the problem. A primary objective is to maintain, improve and contribute to the consistency of the production processes, recommend and execute upgrades to process control, and take leadership in production/equipment upgrades.

The process engineer will be experienced in the methodology and techniques to produce continuous reinforced composite materials. The lead will be a resource for other process engineers to seek answers to technical questions and general guidance, Additionally, this role will mentor, train and develop the process engineering team.

Please note roles and responsibilities are subject to change with or without advanced notice.

Major duties and requirements:

• Responsible for executing all process engineering activities across a broad range of processes, ranging from manufacturing, process control/optimization, scrap reduction, and to support and lead engineering trials
• Recognizes, implements, and troubleshoots tools by providing root cause and corrective actions (RCCA) to problems associated with impregnation or batch mixing manufacturing processes.
• Lead, mentor and support in establishing and measuring process performance standards associated with quality, waste/throughput.
• Contributes and executes to operational reviews and other efforts leading to safety, process improvements and cost reduction activities.
• Leads and supports in investigations and execute RCCA in operational non-conformances and customer related issues.
• Responsible for plans and executes capital projects and process improvement activities.
• Participate in customer site audits/qualifications and visits at Toray.
• Lead and support targeted projects which include defining and documenting product and processing parameters, capability, cost reductions and manufacturing.
• Evaluates, troubleshoots, and solve quality processes, safety and process led improvements
• Documenting and creating manufacturing processes and methods per AS9100 (or equivalent) quality system
• Creates and provides training for manufacturing Configurations, Bills of Materials, Routers, Work Instructions, SPC/SQC, and Control Plans using manufacturing engineering best practices.
• Leads all related functions including Manufacturing, Maintenance, Process Technology, R&D, Quality Assurance and Receiving/Shipping to achieve the company's objectives
• Must be able to support multiple projects.
• Assists in responsibility for the safety and environmental issues associated with the manufacturing processes and equipment.
• Supports process engineering and operation department managers in his/her functional activities, and performs other duties as assigned.
• Must be available and willing to work during off hours when needed.

Experience and/or education requirements:

• Bachelor's degree in material science, engineering, chemical, mechanical or related discipline
• More than ten years of experience working in composite materials, aerospace manufacturing industry preferred
• In depth knowledge of statistical analysis, process control, project management, RCCA and FMEA
• Lean and Six Sigma training, green belt required, black belt preferred
• Root Cause, PFMEA, Statistics & SQC/SPC
• Knowledgeable and in depth understanding of business ERP system (Microsoft Dynamic AX or similar)
• Must be able to communicate clearly (written and verbally) in English
• Able to work and communicate with interdisciplinary teams and the…