Manufacturing Engineer - Spray Foam Process

Primary Function:

The Manufacturing Engineer – Spray Foam Process Owner position is responsible for stabilizing and optimizing our foam production processes to ensure the highest quality and efficiency in our manufacturing operations. You will collaborate with cross-functional teams, including SHE, Quality, product design engineers, maintenance, and production, to implement and maintain robust foam manufacturing processes that meet our specifications.

Responsibilities:

• Heavy focus on safety, quality, process throughput, process stability, and uptime
• Create standardized process including all documentation to ensure highest quality, cost-effectiveness, and efficiency.
• Partner with maintenance and vendors to create comprehensive maintenance plan
• Partner with quality to create comprehensive control plan and quality checks to ensure a robust process is delivering good product to our customers. Account for required quality inspector checks
• Lead Continuous Improvement efforts to continually improve the foam process.
• Training and Support: Provide training and support to production personnel on foam manufacturing processes, troubleshooting techniques, and equipment operation.
• Material Characterization: Work closely with material suppliers to understand the properties of different foam materials and their impact on the manufacturing process.
• Optimize and automate changeovers and conveyor sequencing
• Documentation and Reporting: Develop and maintain process documentation, including standard operating procedures (SOPs), work instructions, and Process Flow Diagrams, PFMEA, Process Control Plans. Generate reports and present data on process performance and improvement initiatives.
• Implement SPC tools and monitor and report of process data in real-time.
• Future development of process including innovation in equipment, process, quality inspection/detection and materials
• Cross-functional Collaboration: Collaborate with design engineers, production personnel, quality control, and other departments to resolve process-related issues and ensure smooth production operations.
• Support the day-to-day needs from operations in order for team to meet KPI’s
• Standardization across all lines.
• Key contact between BWC and outside contractors relating to foam area issues and/or projects.
• Partner with Maintenance, Manufacturing Engineering, Technicians and Operations to ensure effective communication on plant equipment issues to optimize uptime.
• Leads the Root Cause Failure Analysis effort to ensure robust corrective actions are implemented
• Coordinate with maintenance, production, and engineering for any major changes to equipment.

Job Requirements:

• Bachelor's degree, preferably in a related or technical field such as chemical, mechanical or electrical engineering or 8-10 years of related experience in an engineering discipline
• Strong understanding of process optimization, statistical analysis, and process control methodologies (Six Sigma).
• Excellent problem-solving and analytical skills, with the ability to identify and resolve process-related issues.
• Effective communication skills to collaborate with cross-functional teams and present complex technical information.
• Self-motivated, detail-oriented, and capable of working independently and as part of a team.
• Hands on approach in a union environment
• Ability to lead teams without direct authority