Process Engineer

Overview

IPS Corporation is a global, market-leading provider of Water and Flow Management Solutions and Specialty Adhesives Solutions for applications where failure is not an option. Founded in 1954 in Los Angeles, CA, IPS began by producing clear cements for laminating acrylic sheet for aircraft canopies. IPS expanded its offering to more than 10,000 products and solutions across industries such as residential and commercial construction, irrigation, pool & spa, marine, and industrial manufacturing.

Today our products are manufactured at facilities worldwide and distributed through a nationwide network of distributors. IPS is a portfolio company of Centerbridge Partners.

Job Title: Process Engineer
Location: Hartsville, TN

The Process Engineer is responsible for improving productivity and acting as a continuous improvement champion. This role aims to reduce manufacturing costs and improve process control to create a safer work environment and consistently meet Weld-On quality standards. The Process Engineer will leverage the IPS Business System to document and improve process and transactional flows, define and enforce standard work, improve setup times and productivity (manual, machine, materials), and problem solve by identifying and implementing countermeasures.

This role will develop processes, forums, tools, training materials, and poka-yokes, and will coach interdisciplinary teams, including hourly associates and salaried professionals, toward improved operational efficiencies. Regular floor presence and operator engagement are required to identify root causes and sustain improvements. The Process Engineer will work with Maintenance, Production, and Materials teams to execute project plans for capital expenditure implementations and report key metrics to business leaders.

• Identify, establish, and monitor data sources to assess performance against safety, quality, delivery, inventory, and productivity (SQDIP) goals/targets.
• Execute identified countermeasures to close gaps between performance and SQDIP goals.
• Own continuous improvement projects to improve facility KPIs such as productivity, inventory, on-time delivery, and scrap.
• Aid and guide manufacturing associates in addressing process gaps, troubleshooting, and resource escalation when needed.
• Create, maintain, and revise manufacturing documentation (standard work, setup sheets, test methods, corrective methods, visual inspection criteria, etc.).
• Analyze, develop, implement, and maintain manufacturing operation sequences, specifications, and equipment requirements for production/assembly of new and existing products.
• Interpret product design requirements into manufacturing process specifications.
• Identify equipment suppliers, secure quotes, assess capabilities, select suppliers based on product trials, and ensure installation and qualification of equipment with excellent process capabilities.
• Lead or participate in new assembly line setup or layout changes.
• Collaborate with Engineering, Procurement, Manufacturing, and Quality to optimize designs for cost, performance, manufacturability, service, and reliability.
• Troubleshoot manufacturing problems and implement sustainable corrective actions; design and implement SPC, poka-yoke, and other process capability and problem-solving tools.
• Design and establish appropriate tests for specification and reliability.
• Establish and implement manufacturing flow charts, standard work, procedures, control plans, and FMEAs as prescribed by the IPS Business System.
• Conduct process audits based on customer requirements.
• Adhere to all PPE requirements and ensure the team follows safe work practices.
• Other duties as needed.

• Bachelor’s degree in Mechanical, Industrial, Manufacturing, or Electrical Engineering
• 3+ years of experience as a Process/Manufacturing Engineer

• Master’s degree
• 5+ years of experience as a Process/Manufacturing Engineer

• Highly proficient in Microsoft Office (Outlook, Excel, PowerPoint, Word)
• Highly proficient with basic drafting software such as AutoCAD, Creo, or Solid Works
• Understanding of engineering material properties, DFM concepts, ergonomics, and poka-yokes; applying tools to manufacturing setup changes and line design
• Ability to design jigs, fixtures, and tooling, preferably with automation where feasible
• Ability to prepare process feasibility studies and process flow diagrams
• Working knowledge of process planning, line balancing, capacity planning, and production ramp
• Experience with Lean Manufacturing principles
• Experience with analytical tools (Structured Problem-Solving, Statistics, SPC, DOE, VSM)
• Experience conducting cost analyses for proposed changes while considering alternatives to reduce costs without sacrificing quality

• Six Sigma Green or Black Belt
• Experience designing and coding ladder logic in PLCs (e.g., Allen-Bradley, Siemens, Keyence, or…