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Process Engineer - Plastic Extrusions

We are seeking a Process Engineer to optimize and support plastic manufacturing operations. The role focuses on improving production efficiency, ensuring product quality, and scaling processes for safety and cost-effectiveness. The ideal candidate will have hands-on experience in manufacturing and plastics processing, with a strong emphasis on process development, troubleshooting, and continuous improvement across extrusion and downstream operations.

Key Responsibilities

• Develop, document, and optimize manufacturing processes for plastic products to improve yield, reduce cycle time, and lower costs.
• Lead root-cause analysis and implement corrective actions for production issues related to materials, equipment, and process variables.
• Collaborate with R&D, quality, maintenance, and production teams to scale new products from prototype to full-scale manufacturing.
• Design and specify tooling, extrusion dies, and process equipment requirements in partnership with vendors and internal stakeholders.
• Conduct trials, process capability studies, and validation activities; establish standard operating procedures and work instructions.
• Train production personnel on best practices, process controls, and safety standards to ensure consistent product quality.
• Monitor production metrics and lead continuous improvement initiatives (Kaizen, Six Sigma) to achieve performance targets.
• Manage material qualification and approval for plastic resins and additives; optimize formulations and process settings for consistent performance.
• Utilize CAD/AutoCAD models to review and improve tooling, fixtures, and die designs where applicable.
• Support cost-reduction projects, including energy efficiency, scrap reduction, and throughput improvements.

Qualifications

• Bachelors degree in Chemical, Mechanical, Plastics Engineering, or related engineering field, or equivalent experience.
• 3+ years of hands-on experience in manufacturing with specific experience in plastics processing (extrusion preferred).
• Proven experience with plastic extrusion processes and extrusion die design; familiarity with plastic extrusions and downstream finishing processes.
• Strong understanding of plastic resins, material properties, and how they affect processing and product performance.
• Proficiency with CAD and AutoCAD for reviewing tooling and die designs; ability to communicate technical drawings to vendors and shop personnel.
• Demonstrated problem-solving skills, including root-cause analysis and structured continuous improvement methodologies (e.g., Six Sigma, Lean).
• Excellent communication and cross-functional collaboration skills to work with production, quality, and engineering teams.
• Experience with process documentation, SOPs, and statistical process control (SPC).
• Preferred certifications:
  Six Sigma Green/Black Belt, or relevant plastics processing certifications.