Manufacturing Process Engineer

Manufacturing Process Engineer

Location
- Lake in the Hills, IL

Schedule- 1st shift

Compensation: $100,000-$120,000 annually

This position serves as the key technical expert for AFC’s PTFE coating operation, where fiberglass rolled goods are coated with PTFE. This position is responsible for standardizing existing coating processes and continuously developing new processes and process improvements to deliver consistent, repeatable, and capable results. This role leads large projects, trains and develops coating operators, and deep‑dives complex quality issues. Expected work split is 70% on shop floor and 30% office work for documentation.

• Serve as the subject matter expert for the end-to-end PTFE coating process, including web handling, tension control, coating application, drying, and cure profiles.
• Define, document, and maintain optimal process parameters (line speed, oven zone temperatures, coating add-on/weight, and tension) to ensure consistent, repeatable output across products, shifts, and equipment.
• Design and develop coating processes for new products, applications, and substrates, translating customer and product requirements into robust, manufacturable process specifications.
• Establish and maintain process control plans, capability studies, and standard operating conditions for the coating line.
• Apply engineering concepts, techniques, analysis, and decision tools throughout each improvement process initiative.
• Drive continuous improvement initiatives that reduce process variation, scrap, and rework while improving yield, throughput, and first-pass quality.
• Apply Lean and Six Sigma methodologies (e.g., DOE, SPC) to standardize processes and systematically eliminate sources of variability.
• Research and roll out new methods, materials, and equipment designed to improve processes and reduce costs, including creating ROI for proposed solutions.
• Identify areas for cost reduction and implement process efficiencies.
• Serve as the lead technical resource to deep‑dive, diagnose, and resolve coating quality issues such as coating-weight variation, marking, wrinkling, adhesion, and surface defects.
• Utilize root cause analysis tools such as 8D, 5-Why, and fishbone to analyze, understand, and correct issues, driving corrective and preventive actions to closure.
• Partner with Quality Assurance to analyze nonconformances, customer complaints, and RMAs, translating findings into permanent process improvements.
• Develop and lead project teams for research and development of new processes and equipment for existing and new products.
• Develop and adhere to project budgets and timelines, delivering large projects on-time and within budget.
• Partner with outside sources, including equipment vendors and contractors, to deliver projects on-time and within budget.
• Effectively manage time and strategically prioritize projects in line with AFC’s needs.
• Train, coach, and develop coating operators on standardized methods, process controls, and best practices to build technical capability and consistency across the team.
• Create documentation to support and implement improved processes and cost reduction (e.g., SOPs, work instructions, CAD designs).
• Mentoring and development of in-direct reports.
• Work in conjunction with other departments’ heads to develop optimal process designs and efficient utilization of resources.
• Follow all safety and quality guidelines for maximum throughput in keeping with corporate policies and goals.
• Ensure the daily safety of all direct reports by promoting and enforcing a safe working environment.
• Monitor performance metrics and implement continuous improvement initiatives.
• Promotes a positive team environment and rewards and recognizes individual efforts.
• Must be a leader embracing and modeling AFC’s Core Values.
• Perform other duties as assigned.

• Bachelor’s degree in Engineering, or a related field.
• 5+ years of experience in a manufacturing, process engineering, or a related role.
• Experience with plastics manufacturing, continuous manufacturing, or similar processes that are dependent on time, temperature, tension, and pressure. PTFE, dispersion coating, or web-handling experience is a…