Sr. Process Engineer- Molding

Location: Yocumtown

Position:
Sr. Process Engineer (Molding)

Location:

Etters, PA

RESPONSIBILITIES:

Function:

To conceive, plan, coordinate, develop, qualify and implement Standard & Molding
process technology meeting our cost and capacity objectives against customer
requirements. Responsibilities include all aspects related to the
implementation (materials, tooling, equipment), operability and performance of
new or existing Molding processes, their modifications and related
documentation.

Engineering Tasks:

1. Coordinate project tasks and deadlines in maintaining project schedules and
budgets. Solicit internal and external resource support to meet project
timelines.

Participate in definition of overall project plan and schedules for
development projects in meeting time to market (TTM) objectives.
Act as a consultant to management in assessing project aspects, feasibility
and risks and in making technical recommendations for alternatives to achieve
objectives against delivery schedules.
Interface with vendors, quality, product engineering and manufacturing to
assure capability and/or compliance in meeting process, product, delivery, and
safety/environmental objectives.
Coordinate equipment transfer and training of personnel for start-up
facilities

2. Discovery & Definition focuses on early involvement with the product/process
conceptualization to determine characteristics/requirements that meet product,
manufacturing and customer objectives.

Define processes inclusive of process specifications, setup sheets, control
charts, operating procedures, spare parts lists and preventative maintenance
plans.
Provide input to define siting (facilities), area layout and infrastructure
requirements.
Define the process steps and sequence of operations, material handling and
process control needs and to the extent possible, the preliminary process
layout.
Define process flexibility requirements based on proposed product
configurations.
Define the supply chain from raw material to customer application.
Define the process step cycle times, efficiencies, yields and step
relationships to include dynamic modeling as required for process and line
balance assumptions. (Arrangement, Rates, Balance, Yield, Utility, Capacity)
Product cost estimates inputs for each level of approach.
Product/Process FMEA and risk assessment activities.
Define critical product/process parameters.
Mold Flow analysis to determine optimum fill pattern and resultant part
deformation
ProE product manipulation to simulate design variations in support of design
for manufacturability (DFM) and High Volume Manufacturing (HVM)

3. Development focuses on deriving, characterizing and controlling specific
techniques.

Analysis of defined risk areas and experimentation, proof of principle
tooling, feasibility studies, capability studies, detailed design and analysis,
DOE, Passive data collection (PDC) and basic technology searches and
development.
Develop prototypes of specific tools and equipment to execute (and validate)
a defined technique that would ultimately support manufacturing requirements.
Develop and understand material processing behavior within specified
processes or when subjected to a given technique. (both for FCI in-house and the
end customer application)
Characterize process for the purpose of identifying and eliminating
variability (natural and special) so that process limits can be clearly
identified and achieved.
Characterize the behavior of materials within processes for the purpose of
understanding variability and the establishment of controls through statistical
practices.
Qualify process criticals to required levels through product/process
correction actions driven by root cause analysis that incorporate statistical
practices.
Identify process limits for product design to determine what is expected,
day in and day out, under control and at defined levels of efficiency and
profit.
Maintain a base knowledge of key technologies.
Share technologies and best practices throughout the company.

4. Deployment focuses on the transition and delivery to manufacturing.

Interface with site management, quality, engineering, accounting,
purchasing, materials management and other departments throughout all project
phases in the procurement and transfer of processes.
Deliver process specifications, setup sheets, control charts, inspection
plans, operating procedures, spare parts lists and preventative maintenance
plans.
Transfer established best practices to the receiving site.
Coordinate equipment transfer and training of basic personnel
Provide training, guidance and support to production and specialized
personnel.

5. Sustaining Engineering to extend product life cycle and offer product line
extensions.

Troubleshooting - Hands-on processing and mechanical maintenance.
Understanding of electrical circuits a plus.
Audits - Process, procedural and new trainings.
Mold tool expansions.
Succession planning, Product Line End-Of-Life assessments.
Monitor production operations to Key Process Indicators (KPIs)
Review and optimize spare parts supply chain.
Maintain and update…