Process Engineer (nonwovens)

Process Engineer

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, PPRA's, 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, FMA's, MCA's, 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, DOE's, and other studies so causes & effects can be identified). Drive continuous improvement with respect to quality (1^st 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 user's 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
• Excellent 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