Sr Process Engineer

Sr Process Engineer

Job Location:

McDonough, GA 30253

The Sr Process Engineer reports to the Manager, Manufacturing Engineering and is responsible for providing engineering expertise in the areas of thermoforming process development and improvement. They support the launch of new products, continuously improve existing products and processes, provide advanced level process troubleshooting support, process training, and data analysis. The role identifies areas for improvement and participates in continuous improvement activities to reduce product and process variability and improve production efficiencies.

To perform this job successfully, an individual must be able to perform each essential function/duty satisfactorily. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions. Other duties/functions may be added or assigned.

• Provides technical expertise and project management support relating to process improvement projects for new and/or existing products.
• Works with manufacturing staff, developing process engineering documentation, systems, and auditing procedures. Areas of expertise include applicable materials and equipment knowledge.
• Performs manufacturing performance analysis to reduce processing costs through creative engineering and proactive procedures.
• Performs process capability studies and root cause analysis for resolution of manufacturing problems and assists with implementation of corrective actions.
• Coordinates with plant personnel and establishes process improvement teams for cost savings opportunities.
• Develops and maintains SMED activities to decrease mold changeover times to less than 4 hours on preheat machines and 2 hours on contact heat machines, documenting accordingly.
• Ensures all molds are running at the BOM standard cycle time or better and that any changes are documented to maintain IPC procedures.
• Provides detailed technical guidance and training to thermoforming machine operators, setup mechanics, and electro‑mechanical technicians; develops and documents standard training practices.
• Provides full support and leads the commercialization process, working different hours or shifts with minimum notice.
• Provides process support to IPC Remote Facilities, traveling if necessary with short notice.
• Works swing shift, preferably once per week, to develop second‑shift technical staff and ensure consistency of work.
• Acts as liaison to the Central Engineering Department for equipment RFPs, RFQs, commissioning of new equipment, analysis of facility infrastructure needs, and design improvements for manufacturing equipment.
• Acts as liaison to the R&D Department to evaluate, recommend, and implement tooling design changes to improve Overall Equipment Effectiveness.
• Maintains strong relationships with vendors to provide technical guidance in new equipment selection, upgrades, and troubleshooting.
• Generates, maintains, and adheres to project expense and capital budgets.
• Maintains a neat, safe, and clean environment and strictly enforces safety standards.
• Supports building a strong cross‑functional team across all departments.
• Leads by example, maintaining a strong professional demeanor and a "can‑do" attitude.
• Ensures established process parameters surpass company operating efficiency standards.
• Accurately and systematically records data used to analyze set‑ups, changeovers, and processes.
• Will perform other duties as assigned.

• Comply with the EH&S Policy and applicable regulatory and company EH&S rules and requirements.
• Report unsafe conditions or practices that may adversely impact the environment, ensuring prompt resolution of potential hazards.
• Attend scheduled EH&S training programs.
• Actively support the organization’s efforts to meet or exceed EH&S goals and plans.
• Recommend improved EH&S practices.
• Practice safe work habits and follow general safety procedures such as proper lifting, bending, ergonomics, proper use of equipment, and use of personal protection equipment (PPE).
• Ensure all fall protection procedures are strictly adhered to, including the use of harnesses, platform ladders,…