Process Engineer (nonwovens) (Hiring Immediately)

What youll do :

As a Process Engineer, you will own the safety, quality, productivity, procedures, training, maintenance, Gemba, continuous improvement, and sustainability within our South Carolina facility including the following processes : V-lapping, carding, laminating, die cut, and thermoforming of non-wovens

Duties / Responsibilities of this position :

Conduct all activities related to safe storage, handling, processing and disposition of raw materials and the preparation, operation, storage, handling, processing and disposition of equipment in the manufacturing areas. This includes, LPA / BBS audits, PPRAs, Risk Assessments and Spills.

Work with R&D and PD groups during product / process development. Support all process development activities including material development scaleup, plant trials, equipment trials and the implementation / documentation of processing parameters and recipes from raw material to final part. Follow the PDP and ODP processes.

Responsible for the preparation of Process Flow Segment Maps, PFMEAs for all new launched parts in compounding / conversion areas. Utilize part prints, DFMEAs, material specifications, FMAs, MCAs, Formula Recipes and equipment controls / limits as reference for their creation. Work with the quality department to see that these are carried over into the control plans and floor paperwork.

Lead all activities related to process launches including investigations, feasibility, proposals, trials / runoffs of processing equipment. Project Manage the recommended processing equipment including design reviews, equipment signoffs, run at rates and capability studies to produce any existing or new material / products at quoted / standard rates and efficiencies. Follow the CLP process for all capital expenditures.

Interface with production, quality, support technicians and maintenance technicians to troubleshoot and eliminate material quality and process failure issues (including Gemba, Kaizen, RedX, Is / IsNot, DOEs, and other studies so causes & effects can be identified). Drive continuous improvement with respect to quality (1st Pass Yield) and productivity (OEE).

Establish parameters / limits based on the statistical capabilities (6 sigma principles) and the OSI data of the process to produce consistent quality materials and products. Ensure for each manufacturing line, the process inputs are meeting / exceeding their requirements by review and analysis and their outputs are supported.

Provide systems and / or processes that take into account the end users function, timing, cost, safety, environment, ergonomics, cycle time, ease of set up, maintainability and manufacturability within any of the following processes : V-lapping, carding, laminating, die cut, and thermoforming of non-wovens

Establish and maintain safety checklists for all manufacturing processes including V-lapping, carding, laminating, die cut, and thermoforming of non-wovens

Job Requirements :

Knowledge / Skills / Abilities :

A BS or MS in Engineering preferred

2-5 years processing experience in non-woven manufacturing including carding fibers

xcellent communication skills

Project management

Effective analytical and problem-solving skills / experience

Knowledge of materials, mechanical and electrical systems

Ability to travel as needed

Training :

CAD experience (ex. Solid Works, AutoCAD, Pro-E) preferred

P&ID understanding desired

Experience with QS / TS / ISO - APQP, PFMEA, control plans

Microsoft Word, Excel, and Power Point, control / programming systems, database systems

Red X / 6 Sigma training and / or certification desired

Project management

Core Competencies : Performance Driven

Communication

Customer Centric

Passion / Values

Creativity / Innovation

Safety / Sustainability

Collaboration

Expertise

Physical Demands Analysis :

Occasional lifting, pushing and pulling up to 50 lbs.

Occasional carrying up to 50 lbs.

Frequent use of small handheld tools

Frequent computer work using keyboard and mouse

Frequent sitting at desk

Frequent use of computer monitor

Frequent standing and walking

Occasional bending, stooping, twisting or balancing

Rare crawling or kneeling