Industrial Process Engineer

Description

Job description

We have over one million square feet of manufacturing space in Rome, NY and have now expanded into Mebane NC! We are an employee-owned company, competing in the architectural, electrical, telecommunications, air conditioning, industrial machinery, equipment, antimicrobial, and other emerging markets. We proudly work as a team in a safe, environmentally sound and ethical manner to achieve absolute customer satisfaction through superior quality and reliability.

Summary:

Member of the Mebane Plant Operations Team.  Working in a team environment, the successful candidate will be responsible for oversight of three main areas:

(1) Process Engineering. Working with hourly operators and production supervisors to provide day-to-day process and quality assurance functions.  Monitor, control and make recommendations for improvements to various phases of manufacturing processes and equipment. Specify processing parameters to manufacture products to meet customer product requirements. 

Must have strong presence on the production floor and complete daily tasks to monitor process during development. Must be able to interpret and analyze data to generate meaningful and sustainable process improvements as pertaining to the production system. Leads Mebane customer complaint process.  

(2) Production scheduling.   The responsibilities of this role will involve a significant amount of interaction with Revere's Rome, NY Customer Support and Quality Engineering Team.  These tasks will include, but are not limited to, providing delivery dates to customers, scheduling stock replenishment orders, expediting orders, working w/ Supervision to relieve bottlenecks, monitoring inventory, and analyzing on-time production metric.

(3) Continuous Improvement.  Work with Rome, NY’s Continuous Improvement Team and the Rick Harris Lean Practitioner to Lead Revere South’s implementation of the Rick Harris Lean System in the Mebane facility.  Facilitate monthly meetings with the Lean Practitioner and Mebane Operations group.  Implement agreed upon action plans.      

Duties and Responsibilities:

• Required travel to Rome, NY for training period and periodically as required.
• Implement and drive the production schedule to ensure an optimization of production resources to meet market needs, customer delivery and lead time requirements.
• Alignment of supply and demand across production areas to ensure clear direction and visibility.
• Work with a team to design and implement an efficient production system utilizing value stream mapping, WIP supermarkets, inventory pull signals, and clear visuals.
• Work with manufacturing to expedite operations where necessary to minimize impact on customers and establish a recovery plan for customers if commitment date cannot be met.
• Coordinate with Quality Engineering, Customer Support, and Production teams to create the best possible production plan. 
• Analyze key datasets, identify opportunities for improvement, and create and execute sustainable improvements to:

1. Production cycles
2. Process yield
3. Late orders
4. Lab results

• Attend periodic meetings with operations, quality, continuous improvement, sales and marketing.
• Report on key process and product metrics to various levels of the organization
• Investigate production process needs to coordinate and implement projects and action plans.
• Determine alternative processing options to best utilize available capacity on mill machinery. 
• Design and execute experiments to drive process/product improvements
• Utilize process engineering methods to create and modify:

1. Product masters. (Product descriptions)

2. Process masters. (Process Routes)

3. Customer element files. (Testing Requirements)

4. Packaging instructions.

5. New material request documentation for new and experimental materials used in processing and or testing. 

• Work with Quality Engineering to analyze and respond to customer complaints and corrective action requests:

1. Investigates and reports root cause and corrective actions on customer complaints. 

2. Refer off-quality products to affected customers through customer support. 

3. Visit customers, outside processors and MRO vendor’s plants and offices as necessary.

• Review and disposition of lab test failures and other non-compliant products
• Develop and maintain Process FMEAs for production equipment
• Apply technical applications of process engineering:

1. Perform capability and control statistical studies internally and externally requested. 

2. Complete and maintain various APQP demands, including PPAP’s capability studies, part warrants, gaging R&R, process flow   diagrams, etc. 

3. Use various diagnostic equipment and tools to monitor various process parameters. 

4. Perform simple laboratory testing such as PH, hardness, conductivity when necessary. 

5. Work with outside vendors to identify the most economical raw materials and supplies used in production.

6. Conduct process walks to observe material, processes and operator behaviors. 

• Write and update work instructions, quality assurance plans, and other documentation.
• Lead and or participate in mill tours to visiting customers, vendors and community members. 
• Perform internal audits, including the writing of audit findings and leading discussions at audit closing meetings.
• Participate in various production and quality teams. 
• Provide operator support and learning

Qualifications:

• Analytical and problem-solving capabilities, ability to overcome obstacles.
• Exposed to Lean Manufacturing concepts. Working knowledge of pull systems and kanbans a plus.
• Strong organizational skills with attention to detail.
• Proficient in use of MS Excel and PowerPoint.
• 3 years of experience in a technical position in a manufacturing environment. 
• Familiar with various quality and process control techniques. 
• 3-5 years of experience in the manufacturing and quality management of primary metals (copper, steel, aluminum), mechanical and physical material testing of metals and experience In problem solving methodology, containment and corrective action processes, APQP techniques, and thorough knowledge of statistical process control techniques.

Special Demands:

• While performing the duties of this job, will be regularly exposed to work near moving mechanical parts. 
• May be exposed to wet or humid conditions. 
• May be regularly exposed to high noise environments. 
• May be exposed to chemicals used in the manufacturing process 

Education /   Training:

Minimum:

• Bachelor’s degree in engineering, operations management, mathematics or equivalent experience. Knowledge of statistical techniques is   a plus. Proficiency in Microsoft Office products. 

Preferred:   

•  Six sigma black belt certification and AIAG certification. 
•  Experience with heavy industrial machinery.
•  Process, Quality, Production Planning or Continuous Improvement experience in manufacturing environment. 
•  Experience with lean manufacturing concepts

Benefits:

• 401(k)
• 401(k) matching
• Dental insurance
• Health insurance
• Paid time off
• Vision insurance

Salary : $78,000 - $94,000