Mechanical Process Engineer ll

Toray Advanced Composites (TAC) is a leading supplier of advanced composite materials for the aerospace, sporting goods, motor sport and industrial markets. You will find our thermoset composite products on nearly every satellite, space launch vehicle, unmanned aircraft, military and commercial aircraft in production today. TAC also provides composites materials to industrial and recreational applications including mountain bikes, medical prosthetics and sports equipment.

Our thermoplastic prepregs, known in the industry as Cetex®, are found in a wide range of commercial and military aircraft, including large wing structures and interior applications like seats and galleys. Our Cetex products are available in unidirectional tape or fabric form in a variety of engineered thermoplastic resins including PEEK, PPS, PEI as well as a full line of performance thermoplastics including Nylon, PET, PC/ABS, HDPE, and PP.

Summary of Functions:

The Mechanical Process Engineer II will work independently, with minimal supervision to take on technical ownership to evaluate manufacturing methods and equipment, develop and enhance production equipment capabilities, assembly methods, control standards, etc., and to improve and optimize production outcomes. The Mechanical Process Engineer II will be responsible for the complete and technical oversight of a continuous production process, to ensure maximum up-time, with highest efficiency and excellent quality. Additionally, the encumbent will provide production, engineering, and maintenance/facility support with new process development and equipment integration. This is a hands-on process/mechanical engineering role and will require ingenuity, flexibility and problem-solving capabilities. 

Please note roles and responsibilities are subject to change with or without advanced notice.

Major Duties and Responsibilities:

This role will work independently with minimal supervision to execute the following roles and responsibilities:

1. Support process engineering and maintenance departments with:
2. Responsible for executing most of the process engineering activities across a broad range of process and machine design and integration, ranging from manufacturing, process control/optimization, and support and lead engineering trials.
3. Recognize and familiarity with root cause and corrective actions (RCCA) analysis to the problems associated with impregnation or batch mixing manufacturing processes.
4. Support and provide feedback in establishing and measuring process performance standards associated with quality, waste/throughput.
5. Contributes to operations and executes to operational reviews and other efforts leading to safety, process improvements and cost reduction activities.
6. Under minimum direction plans and executes capital projects and process improvement activities.
7. Support targeted projects which include defining and documenting product and processing parameters, capability, cost reductions and manufacturing.
8. Evaluates, troubleshoots, and solve equipment/process problems on the production floor.
9. Supporting manufacturing processes and methods per AS9100 (or equivalent) quality system
10. Familiarize with manufacturing Configurations, Bills of Materials, Routers, Work Instructions, SPC/SQC, and Control Plans using manufacturing engineering best practices.
11. Works with all related functions including Manufacturing, Maintenance, Process Technology, R&D, Quality Assurance and Receiving/Shipping to achieve the company's objectives 
12. Must be able to support multiple projects.
13. Assists in responsibility for the safety and environmental issues associated with the manufacturing processes and equipment.
14. Supports process engineering and facility/maintenance department director/managers in his/her functional activities, and performs other duties as assigned. 
15. Must be available and willing to work during off hours when needed.

1. Analyzes existing manufacturing equipment and processes, and designs plans for improvements:
2. Identifies opportunities for improved equipment and process design by observation and evaluating factors such as downtime, equipment efficiency, new technology, quality, etc.
3. Brainstorms with engineering team regarding engineering approaches for improvement
4. Designs solutions to address repeat problems or optimization opportunities
5. Defines equipment needs, makes 3-D drawings and devises test plans 
6. Ensures ergonomic testing and perform/lead the PFMEA
7. Researches vendor, makes parts lists and ensure timely procurement of all components
8. May fabricate/tool, or lead the fabrication/tolling of, parts and equipment
9. May negotiate favorable pricing

1. Implements engineering improvements and conducts post implementation evaluation:
2. Installs or leads the installation of new equipment and performs IQ/OQ and assist with PQ.
3. Evaluates real-time effects on production and workforce utilization 
4. Recommends adjustments to settings and usage
5. May instruct maintenance mechanic teams and machine operators on new equipment functionality and preventive maintenance
6. Conduct periodic observations and tests to maximize implementation effectiveness

1. Plans, manages and oversees engineering projects to ensure on-time, on-cost delivery:
2. Utilizes project management techniques to execute on approved engineering projects
3. Partners with engineering team to develop project timelines and determine costs
4. Designs measurements and metrics to underscore and assess project success
5. Manages budgets
6. Holds others accountable to agreed upon tasks and timelines
7. Communicates any risk to project execution and drives resolution
8. Conducts post implementation study to validate effectiveness of implementation and to derive further improvements

1. Applies design background and technical design skills to all drawings and plans:
2. Transfers complex new ideas into proposals for simple and elegant user-friendly, ergonomic designs
3. Utilizes Inventor, SolidWorks and AutoCAD to generate conceptual layout drawings
4. Attends on-line and in-person training as required to maintain skill sets

Experience and/or Education Requirements:

• Bachelor Degree in engineering, preferably in mechanical or other related discipline
• At least 3 years of professional experience working in design for manufacturing, preferably in aerospace/composite industry
• Proficience with Solidworks, 3D and multipart assembly. 
• Mentorship, training or supervision experience preferred.
• Basic knowledge and understanding of statistical analysis, process control, project management, RCCA and FMEA
• Possesses basic knowledge of Lean and Six Sigma
• Understand root Cause, PFMEA, Statistics & SQC/SPC 
• Has knowledge and basic understanding of business ERP system (Microsoft Dynamic D365 preferably or similar), MES systems
• Must be able to communicate clearly (written and verbally) in English 
• Able to work and communicate with interdisciplinary teams and the leadership team
• Maintain work areas in a neat, orderly and safe manner 
• Follow safety procedures for PPE (personal protection equipment) 
• Previous experience with composites or aerospace is preferred

 Salary Range: $100,000 - $120,000

Toray Advanced Composites employment practices offer equal employment opportunity and does not discriminate against its employees or applicants because of race, color, religion, sex, pregnancy, national origin, ancestry, age, marital status, physical or mental disability, medical condition, sexual orientation, or any other basis prohibited by law. Equal employment opportunity will be extended to all persons in all aspects of the employer/employee relationship, including recruitment, hiring, training, promotion, transfer, discipline, layoff, recall, and termination.