Senior Process Engineer

Job description

Job Purpose

This position supports the engineering department and has a main responsibility for optimizing and improving our extrusion processes, ensuring product quality, and driving efficiency. This role involves designing, developing, and implementing extrusion processes, troubleshooting equipment issues, and collaborating with cross-functional teams to achieve production goals. The ideal candidate will possess a strong understanding of raw materials, extrusion equipment, and process optimization techniques.

Duties and Responsibilities

The essential functions include, but are not limited to the following:

• Demonstrates high proficiency in operational knowledge of both single-screw and twin-

screw extrusion equipment and associated downstream equipment such as vacuum tanks, calibration tables, pullers, cutters/saws, etc.

• Understands and demonstrates knowledgeable in extrusion tool design, die flow, dry and

wet calibration techniques.

• Works with a broad range of extrusion grade raw materials including but not limited to

Rigid PVC, Flexible PVC, ABS, ASA, PE, PP, HIPS, Acrylic, Polycarbonate, TPE & TPE.

• Develops and optimizes the following extrusion processes to meet product specifications

and quality standards: co-extrusion, tri-extrusion, dual durometer extrusion, tubing &

pipe extrusion, multi-hollow extrusion, and capstock extrusion.

• Collaborates creatively with other stakeholders and presents innovative solutions for

problem-solving, trouble-shooting, processing techniques, tool design, and overall

optimization of extrusion processes.

• Develops and utilizes various process monitoring techniques.
• Documents processes for repeatability
• Conducts process trials to improve efficiency and reduce waste
• Analyzes process data, investigates quality issues and implements corrective actions to

ensure consistent product quality.

• Identifies equipment upgrades and improvements to enhance performance.
• Identifies and implements continuous improvement initiatives to enhance efficiency and

reduce costs.

• Leads, facilitates and/or participates in problem-solving and root cause analysis

activities.

• Provide technical support and training to production personnel.
• Stay up-to-date on industry trends and advancements in extrusion technology.
• Regular attendance pattern.

Qualifications

• Bachelor's degree in Chemical Engineering, Mechanical Engineering, Polymer Science, or

a related field, is strongly preferred.

• 8- 10 years of experience in the following extrusion processes: co-extrusion, tri-extrusion, dual durometer extrusion, tubing & pipe extrusion, multi-hollow extrusion, and capstock extrusion.
• Strong knowledge and prior hands-on experience with both single-screw and twin-screw extrusion equipment and associated downstream equipment such as vacuum tanks, calibration tables, pullers, cutters/saws, etc.
• Strong knowledge and experience with a wide range of extrusion grade raw materials

including but not limited to Rigid PVC, Flexible PVC, ABS, ASA, PE, PP, HIPS, Acrylic,

Polycarbonate, and TPE

• Understands extrusion tool design, die flow, dry and wet calibration techniques.
• Understands key principles of a quality management system including Statistical Process

Control (SPC)

• Proficiency in using CAD software and data analysis tools.
• Excellent problem-solving and analytical skills.
• Strong communication and interpersonal skills.
• Ability to work independently and as part of a team.
• Experience with lean manufacturing and six sigma principles is a plus.
• Strong organization and process documentation skills.

Physical Requirements

• Typical office and manufacturing environment
• 8-hour, onsite schedule
• Frequent speaking
• Frequent combination of sitting, standing, and walking
• Frequent keyboarding
• Frequent gross and fine manipulation
• Frequent bending, reaching, pushing, pulling, and lifting of up to 40 pounds.
• Frequent stooping, crouching, kneeling