What are the responsibilities and job description for the Senior Process Engineer position at Gyproc?

As a Senior Process Engineer, you will play a pivotal role in driving process development, efficiency, and improvement initiatives. Additionally, the incumbent is to act as technical advisor to manufacturing engineers, production supervision and marketing. You’ll utilize a multidiscipline, in-depth technical knowledge of engineering principles, theories, and concepts. You will collaborate with both internal and external customers on cost-saving projects, capital expenditures, and troubleshooting. Your focus will be on taking a leading role for the site to optimizing material throughput, enhancing plant profitability, and refining manufacturing techniques, particularly in process robustness, coating technology, and material aspects such as yield, scrap, and material usage variance. Additionally, you will manage various projects, develop preventative and predictive methods to minimize production delays, and ensure quality. This role also involves providing leadership in problem-solving, decision-making, coaching, and implementing site initiatives.

Key Responsibilities :

Design and Development : Lead the design and development of manufacturing processes, tooling, and engineering documentation for new products, ensuring they meet or exceed customer requirements.
Continuous Improvement : Recommend, initiate, and deliver projects aimed at improving production efficiency, equipment, and processes to achieve performance, quality, delivery, and financial goals.
Capital Expenditures : Prepare internal documentation and coordinate the implementation of capital expenditures.
World Class Manufacturing Projects : Lead projects from conception to implementation, including cost savings analysis, feasibility studies (DOE, data analysis), and project execution.
Process Optimization : Research and recommend changes to manufacturing processes to increase efficiency, reduce costs, improve product quality, and enhance health, safety, and environmental standards.

Essential Functions :

Shows exceptional safety leadership skills through displaying safe work practices at all times and actively participating in plant Health & Safety & Environment efforts. Encourages and empowers other staff to do the same.

The incumbent is the technical expert for coating, laminating and converting processes and products, and must have the ability to effectively understand the various manufacturing processes in detail. The ability to work as part of a team and to lead a team to achieve goals is also essential.

Applies engineering principles and concepts from multiple disciplines to improve production; to develop and implement new processes; and to solve problems related to product and process quality, performance, and cost. Must have manufacturing experience with various raw film materials (PET, TPU, HDPE, HIPS, etc), mixing, solvent coating / drying.

Performs statistical analysis of process variables and rejection rates, interprets data and leads resulting process and product improvement projects. Creates, implements, and oversees vital quality and process control procedures.

Participates in cost control programs and the standardization of processes and procedures. Frequently interacts with production personnel to evaluate and solve production problems and to advise on process capability and customer demands.

Works closely with Marketing, R&D and production management in developing and testing new products and processes before they are introduced into production. Coordinates the integration of prototype items and new materials into the manufacturing process.

Ensures adherence to the quality guidelines set forth in ISO9001. Applies lean manufacturing concepts (SPC, 5S, Kaizen, 6sigma) toward improved material formulations, mix quality, product quality, process flow and equipment performance.

Requirements :

This position requires the skills associated with a Master of Science Degree in Polymer Processing, Chemical or Mechanical engineering discipline with 5-7 years of experience, or the skills associated with a Bachelor of Science Degree and 10 years of experience.

Strong analytical, statistical and root cause analysis skills a must.

Experience with solvent mixing, coating, lamination, and converting processes and equipment is required.

Past experience with SPC and familiarity with 5S, Kaizen and Lean manufacturing principles strongly preferred.

Excellent interpersonal, oral and written communications skills and the ability to work effectively across all levels of the organization and with customers are necessary.

Proficient in Excel, Word, Powerpoint and any ERP and MES software is essential.

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