Process Engineer

2 months ago

Lakewood, United States NeoGraf Solutions LLC Full time
Job DescriptionJob Description

About Us

NeoGraf has been the world leader in our industry for more than 140 years, developing the most comprehensive graphite solutions since 1881. Our products are why some of today’s most technologically advanced products can perform and work the way they do. Our depth of knowledge, training, understanding, and discipline is unmatched in the market, and there’s no stopping where we can go from here.

As part of its vertical integration strategy, NeoGraf is establishing specialty polymer compounding capabilities to provide our customers with the option of receiving our products in polymer masterbatch form or a fully formulated compound. We seek an experienced Process Engineer to join our progressive team and drive this strategy forward. This is an excellent opportunity to join the company early in this new strategy and directly contribute to its success.

Primary Job Function

As a vital organization member, the Process Engineer will integrate manufacturing processes, equipment design, product formulations, and procedures to drive efficiencies, enhance product quality, and optimize material yields. In addition, the Process Engineer will coordinate and support rapid prototyping efforts for new product development.

The ideal candidate will have extensive experience in process engineering within the polymer industry, focusing mainly on twin-screw extrusion, and have a working knowledge of other compounding techniques, including their advantages and disadvantages related to the type of compound and will serve as a role model by implementing lean / six sigma best practices and promoting our safety culture.

Description of Responsibilities

  • Process Optimization, Efficiency Gains, and Troubleshooting:
  • Design and optimize screws for twin-screw extruders to accommodate different materials
  • Set up the compounding process, using side feeding and vacuum degassing features where necessary.
  • Define and execute process development experiments using design of experiments (DOE) methodology, including data analysis and documentation.
  • Coordinate with colleagues in purchasing, scheduling, manufacturing, and technical personnel to plan and execute trials and scale-ups.
  • Identify, develop, and implement cost-reducing improvements to manufacturing processes.
  • Identify and implement process and quality improvements in current processes.
  • Provide technical support and troubleshoot problems in operations processes.
  • Lead the transition from experimental to full-scale production volumes for all compounds at the facility, including coordinating and reporting on production trials.

Description of Responsibilities (Continued)

  • Laboratory and Testing
  • Utilize and operate a range of essential laboratory equipment to support the optimization of processing methods, including measurements of Melt Flow Index, Density, Bulk Density, and Pellets per Gram.
  • Coordinate advanced analytical testing of samples produced in process and formulation studies.
  • Training and Compliance
  • Support the Director of Operations with employee training on new equipment, processes, or procedures.
  • Execute continuous improvement initiatives (prioritized by the management team) using Lean Six Sigma methodologies.
  • Monitor and seek to improve equipment effectiveness of all plant processes.
  • Ensure that safety, engineering, and proper ergonomics are designed into new or revised processes and equipment.
  • Safety and Safety Culture
  • Ensure all manufacturing processes comply with safety standards and regulations.
  • Develop and implement safety protocols and procedures to minimize risk and ensure a safe working environment.
  • Conduct regular safety audits and risk assessments to identify potential hazards and implement corrective actions.
  • Lead safety training sessions for employees, focusing on safe equipment operation and handling of materials.
  • Promote a culture of safety awareness and continuous improvement among all team members.
  • Investigate and report any safety incidents and proactively prevent recurrence.
  • Participate in safety meetings and contribute to the development of safety initiatives.

Knowledge and Skills

  • Minimum of a Bachelor’s degree in Polymer Engineering, Polymer Science, Chemical Engineering, or a related field. A Master’s degree is preferred.
  • At least ten years of experience in process engineering, specifically with twin-screw extrusion processes for compounding polymeric materials.
  • Working knowledge of other compounding techniques, including Banbury internal mixers, Farrel Continuous Mixers (FCM), and Buss Ko Kneaders.
  • Experience in compounding a wide range of thermoplastic and reactive compounds.
    1. Examples of thermoplastic materials: polystyrene, polycarbonate, ABS, Nylon, polypropylene, polyethylene, and polysulfone.
  • Examples of reactive compounds: silane grafted polymers and maleic anhydride grafted polymers.
  • Familiarity with Lean & Six Sigma methodologies; Green Belt certification is highly desired.
  • Comprehensive understanding of OSHA and other relevant safety regulations.
  • Experience in developing and implementing safety protocols in a manufacturing setting.
  • Strong commitment to fostering a culture of safety and continuous improvement.
  • Ability to conduct thorough safety audits and risk assessments.
  • Strong analytical and problem-solving skills, with the ability to analyze complex data sets.
  • Experience with laboratory equipment and testing methods for the QC of polymeric compounds.
  • Proficiency in AutoCAD or similar engineering design software.
  • Knowledge of PLC control systems and dust collection systems is highly desired.
  • Exceptional mechanical and mathematical abilities.
  • Excellent communication, organizational, and teamwork skills.
  • Commitment to safety and high housekeeping standards.
  • Ability to read, interpret, and analyze blueprints and schematics.
  • Results-driven with the capacity to own projects from inception to completion.

Working Conditions

Non-climate-controlled factory environment; Concrete flooring that may be slippery at times.

Frequent lifting, standing, walking, bending, twisting, and stooping are required in this position. Exposure to audible and visual alarms, lights, etc., may be required. PPE may be required as appropriate.

Travel up to 15% (supplier/customer visits, conferences, continuing education, etc…)

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