Sr. Process Engineer

The Senior Process Engineer is responsible for developing, analyzing, and implementing new or

modified process technologies, products, equipment, and systems for all Plant 90 manufacturing

processes under the guidance of the Plant 90 Plant Manager. This position provides leadership

for the site process engineering team regarding problem solving and supports production

personnel to improve quality and productivity while aiming to reduce operating costs. The Senior

Process Engineer prioritizes and implements process improvements and controls to reduce

defects, scrap, rework, and downtime in production. Developmental work is coordinated with all

necessary departments and is performed in accordance with acceptable and customary

manufacturing practices while utilizing quality improvement techniques and experimental designs

Duties & Responsibilities:

• Process improvement - Uses process data (defect, scrap, rework, OEE, etc.) to identify process weaknesses and develops process methods, materials, training, and equipment modifications to obtain improvement. Various quality methods are utilized, as is the bar code information system. Participation and leadership of task groups is required. Interaction with production personnel is an integral part of the improvement process. Support Carlisle Operating System initiatives through training, participation in events, follow up and assisting with the training and coaching of others.
• Technical assistance to production personnel - Helps resolve problems relating to materials, methods, and equipment. Develops and employs expertise in all areas of the plant (compounding, extrusion, web handling, adhesive coating) Utilizes extensive knowledge and experience with manufacturing processes to identify root causes and implement permanent corrective measures. Coaches and teaches production personnel to assume "line ownership of quality."
• Process control - Verifies and maintains control of production processes and variability through the development, writing, issuing and revision of written process specifications. Implements and trains pertinent positions in the use of statistical process control methods to identify factors influencing process stability. Controlled factors include scrap, defects, rework, throughput rates, and dimensional characteristics as well as various aesthetic factors pertinent to customer satisfaction.
• Project management/support - Assumes leadership and responsibility for various projects in the plant including but not limited to: introduction of new technology and cost reduction; support and participation in the evaluation of R & D trials and experimentation for the development of new products, processes, and cost reduction; new product or process start-up, and the justification of new equipment or capital to improve processes.
• Development and maintenance of information systems. Responsible for maintaining funnel of losses and opportunities as they relate to Safety, Quality, Delivery, & Cost. Implementing best practice layered audits of key equipment maintenance. Defining 3 year technical investigation roadmap for the facility.

Education

• BS in Engineering or Science with math through algebra and geometry, chemistry, and physics.
• Coursework in statistical process control and plastics technology is a plus.

Experience

• 5-7 years of plastic processing experience in a technical support role is desirable but not required

Equipment, Materials, and Data Used:

• Equipment used on the job: Plastic extruders, calenders, sheet dies, unwinder/winder equipment, packaging line, compounding/blending equipment, scales, balances, melt flow index, optical microscopes, tensile testers, and color testers
• Materials used on the job: Raw materials including polymer pellets, compounded concentrates, neat powders, powder blends, reinforced fabrics (scrim), finished membrane, films, solvents and lubricants
• Data used on the job: Safety data sheets, raw materials, tensile, color, and melt flow testing, control charts, dimensional control measurements, operating conditions, bar code reports, R&D reports, SPC reports, customer generated data, machine utilization reports, maintenance repair reports, and quality control report

Work Environment:

• 60% of time is spent working in the plant on projects, observing processes, and troubleshooting
• 40% of time is spent working in the office writing reports, working on a computer, and conducting data analysis
• Plant ambient temperature in the summer matches the outside temperature
• Plant is heated in the winter
• Exposure to solvent fumes and loud noise levels (PPE Provided)
• Fast paced production environment that can be stressful and demanding