Process Engineer

Process Engineer

Thales people architect identity management and data protection solutions at the heart of digital security. Business and governments rely on us to bring trust to the billions of digital interactions they have with people. Our technologies and services help banks exchange funds, people cross borders, energy become smarter and much more. More than 30,000 organizations already rely on us to verify the identities of people and things, grant access to digital services, analyze vast quantities of information and encrypt data to make the connected world more secure.

This is an on-site position in Montgomeryville, PA.

This position is eligible for the Americas referral program for external candidates: Tier 1 - $2500 Referral Bonus.

The Process Engineer is a member of the Engineering team who is responsible for coordinating process engineering projects of all types and supporting equipment improvements as necessary. This position is responsible for development of risk assessments, comprehensive qualification tests, and robust industrialization plans related to the introduction of new products and materials into the manufacturing plant. The Process Engineer is also responsible for conducting equipment and process capability studies identified as needed by management or identified in the industrialization plan. They will be responsible for developing and implementing equipment and process controls that facilitate an excellent production environment by ensuring equipment and processes are statistically capable and in control. The Process Engineer will troubleshoot manufacturing materials, methods, equipment and product issues by interacting with operators, maintenance and quality teams as well as with engineering peers and corporate support teams.

Key Responsibilities

• Coordinating, implementing, and qualifying process-related engineering changes
• Implementing lean manufacturing techniques into production cells
• Preparation of change management documentation around product or material changes or new process introductions
• Assisting in new-product qualifications and introductions
• Coordinating appropriate maintenance support for projects as necessary
• Supporting manufacturing teams as required including training on methods of operation
• Monitoring and continuously improving manufacturing quality and efficiency (e.g. reduce cycle time, yield improvement, process controls, etc.)
• Assisting maintenance technicians on projects that require a high level of engineering analysis
• Coordinate inter-company technology and equipment transfers
• Support production automation by modifying or creating tools to eliminate the possibility of

Minimum Requirements

• B.S. or equivalent in Mechanical, Electrical, Materials, or Manufacturing/Industrial Engineering
• 3-7 years of process engineering experience in a manufacturing facility
• Strong written and inter-personal communication skills
• Demonstrated ability to effectively interact with employees in a culturally diverse environment
• Experiential knowledge of Lean Manufacturing concepts is essential (SPC, DMAIC, Kaizen, VSM, Kanban, TPM, 5S, Fishbone, FMEA, etc.)
• Desire and ability to collect, analyze and interpret operating data and use it drive improvement
• A high level of competence with Microsoft Windows PC and Microsoft Suite (Excel, Word, Project, Outlook, and PowerPoint) required
• Proven decision making and analytical thinking capability
• Drive root cause analysis and corrective actions for non-conforming processes
• Act as interface with central engineering teams on machine and technology transfers
• Willingness to develop new methods and processes
• Aptitude for and interest in new technologies
• Must be able to perform essential functions of this position with or without a reasonable accommodation

Preferred Qualifications

• Equipment knowledge and experience in plastic card manufacturing a plus
• 1+ year of Lean Manufacturing experience preferred
• Experience with CAD and statistical software packages preferred
• Experience working directly with PLC's and PLC code
• Experience with servo controllers and servo controller logic, pneumatic and hydraulic systems
• Thorough knowledge of electrical/electronic components and equipment including the use of special instruments for diagnostic purposes. Experience with controls and control systems
• Experience with 3D printed parts a plus
• Experience creating reports with databases and tools like PowerBI a plus
• Interest in and understanding of AI tools and Vision Inspection systems a big plus
• Experience and interest in designing and building automated product handling systems incorporating robots, cobots, AGV's and machine vision