Position Summary   The Lead Process Engineer is a highly influential and visible member of the Materials R&D group with responsibility for providing hands-on process engineering expertise and leadership to new product development programs and product improvement initiatives. Primary focus  include all steps contained in melt extrusion processing (compounding and polymer  extrusion). Responsibilities may extend to support roll to roll coated products (compounding, web coating and handling, and slitting operations).   Essential Duties and Responsibilities  

  • Provide process development expertise and support for new product developments. 
  • Manage process improvement initiatives and custom product developments. 
  • Provides expertise to site improvement team leaders and teams in the use of quality tools such as, Failure Modes and Defects Analysis (FMEA, both design and process), Design of experiments (DOE), process capability assessment and development, error-proofing, six sigma, lean manufacturing and Statistical Process Control (SPC). 
  • Conduct DOEs and capability studies to develop product and process parameters and assure robust processes. 
  •  Provides site QA engineering support as part of a site quality improvement/corrective action process teams. Lead investigations into product quality issues; institutionalize corrective actions. 
  • Collaborate with chemists and work with customers and suppliers on product design and material selection to assure robust manufacturability. 
  • Provide process engineering input in technical design reviews. 
  • Provide guidance and mentoring to junior R&D staff. 

  • Cultivate a network of support from cross functional teams (R&D, Operations, Marketing, Purchasing, Sales, and Product Management).    Required Knowledge, Skills and Abilities  

  • BS in Chemical Engineering, Polymer Engineering, Mechanical Engineering or equivalent technical discipline. 
  • Five years or more of experience in a process development role using design of experiments and statistical analysis tools. 
  • Practical hands on experience on process improvements using quality tools that may include but not limited to, Failure Modes and Effects Analysis (FMEA, both design and process), Design of experiments (DOE), process capability assessment and development, error-proofing, six sigma, lean manufacturing and Statistical Process Control (SPC). 
  • Established track record of successful process development through the application of DFSS tools and familiar with stage/gate development process. 
  • Demonstrated skill in solving complex product/process issues. 
  •  Ability to drive change through influencing within and across organizational boundaries. 
  • Ability to train, mentor and clearly articulate statistical and quality / reliability concepts to project teams and to functional management. 
  • Data driven and proactive. 

  •    Desired Characteristics: Knowledge, Skills and Abilities  

  • Graduate degree (M.S./Ph.D.) in an engineering discipline. 
  • The ideal candidate would have 3-5 years of experience manufacturing support in hot melt plastics extrusion or related industry. 
  • Six Sigma Greenbelt or Blackbelt certification a plus.         Position Reports To: Manager, Process Engineering

Desired Skills and Experience

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