R&D Process Engineer

Overview

As an R&D Process Engineer at Footprint, you will be responsible for developing, evaluating, and improving process and equipment methods to enable on-time delivery of new products, cost reduction, decreased cycle and set-up times, quality, and efficiency improvements. You will utilize your statistical knowledge to drive improvement and process changes that improve performance, yield, cost, and efficiency. Additionally, you will be the single point of contact for equipment issues, concerns, and possible continuous throughput improvement ideas and/or projects.

This role also involves setting up process parameters, monitoring equipment through regular testing, creating and overseeing standardized production procedures, and maintaining all documentation for products such as work instructions. You will work closely with cross-functional teams to determine ways to minimize operating costs and enhance equipment performance.

• Develop robust, reliable, effective, and efficient processes and equipment in support of business objectives
• Establish and maintain the process engineering, technical and tooling functions and ensure that robust manufacturing processes are achieved to meet the plant's productivity, delivery, quality, and safety objectives
• Work to continually identify and implement advanced processes and technologies
• Participate in solving quality problems involving research and development equipment, and drive improvement and process changes that improve performance, yield, cost, and efficiency
• Set up process parameters, design of experiments and monitor equipment by conducting regular testing
• Create and oversee standardized production procedures and maintain all documentation for products, such as work instructions; and determine ways to minimize operating costs, such as equipment justification to enhance performance. Role model the cycle of solving problems, documenting the changes, training personnel on the changes and proliferating those changes to the high-volume manufacturing sites
• Produce high-quality documentation that meets applicable standards and is appropriate for its intended audience
• Develop, establish, and ensure appropriate departmental standards, methods, policies, procedures, and documentation are in place and maintained
• Modify or reengineer processes to increase throughput while maintaining or increasing the quality and accuracy of output
• Serve as the lead when it comes to transferring new processes and technologies from the laboratory/bench/pilot scale into full production
• Gather and analyze data and use that data to make recommendations. This includes characterization of current process, quantifying/qualifying potential process improvements and leading validation efforts of newly implemented products/processes.
• Compile data, document work, and prepare reports for both technical and non-technical audiences
• Coordinate and plan to ensure project work meets quality specifications and is delivered on schedule and within budgetary constraints
• As needed, the engineer will travel to Footprint’s high volume manufacturing sites, suppliers, etc. for extended stays to support Footprint’s business objectives
• Understand the development process, suggest improvements, and execute them to improve the development process
• Perform all other duties and responsibilities as assigned or directed by manager

• Excellent written and oral communication skills
• Ability to work on a cross-functional and diverse team
• Ability to manage complexity, manage multiple priorities and prioritize accordingly
• Flexibility and adaptability around shifting priorities in a fast-paced work environment to support 7 x 24 x 365 7 days a week, 24 hours a day, and 365-day operations
• Strong analytical, creative thinking and problem-solving skills utilizing structured problem-solving techniques
• The ability to drive projects and overcome any hurdles that are encountered from pilot to transfer to high volume manufacturing.
• Strong interpersonal, cross-functional teamwork, process improvement and project management skills
• The ability to lead projects through to transfer to high volume manufacturing.
• Role model with…