Process Engineer

1 month ago

Madison, United States Tekni-Plex Full time
Summary/Purpose:

Uses engineering principles, team facilitation skills, and statistical process control tools to measure and improve key processes integral to the manufacturing of printed and unprinted laminated and coated packaging materials for the pharmaceutical and medical device industries. Manages key process controls and develops relevant metrics to ensure process variables are quantified and within control. Manages small capital projects and cross functional improvement teams to improve manufacturing costs, efficiencies and reduce process variability.

Essential Job Duties:

  • Implement lean manufacturing principles. Facilitates cross functional improvement teams with the objective of implementing lean manufacturing principles.
  • Analyze data to identify, propose and execute projects to improve efficiency. Prepares proposals & reports and executes planned projects, including, determining time frames, funding, procedures for accomplishing projects, staffing requirements, and allotment of available resources to various phases of projects.
  • Work directly with machine operators to identify needs and develop solutions; work with Maintenance on equipment modifications and preventative /predictive maintenance to ensure reliability.
  • Identify, propose and execute projects to improve customer satisfaction, through performance and product reliability. Develops / improves product reliability, performance consistency and cost effectiveness.
  • Provide manufacturing waste, Overall Equipment Effectiveness and other key operational reports to the site leadership team.
  • Develop thorough knowledge of all manufacturing processes and equipment; monitor and assess all equipment performance; develop requirements and participate in CER development for new/modified equipment.
  • Statistically evaluate process parameters; assess impacts of material changes to efficiency and process integrity. Reduce scrap levels and increase yields.
  • Develop strategies for process improvement and evaluate impact of such changes; actively participate in and/or drive root cause analysis and process improvement efforts.
  • Be the plant liaison for trials and participate in all associated meetings and activities to ensure success.
  • Support process monitoring and vision systems (Dr. Schenk) to assist Operations and Quality with defect identification.
  • Evaluate and modify the Enterprise Resource Planning system and bill of material routers based on actual performance and the most efficient process work flow.
  • Participate in customer complaint system with the goals of prevention of future occurrences and complaint avoidance.
  • Promotes worker safety by:
    • Actively assessing activities on a constant basis to ensure no unsafe actions or results will occur.
    • Stressing safe working practices as a condition of employment to associates.
    • Assisting in safety audits of employee behaviors to ensure compliance with safety rules and guidelines, as well as housekeeping audits and surveys.
    • Participating actively on the plant-wide safety team.
    • Ensuring the housekeeping in the immediate and surrounding work area is maintained or improved to the highest level possible.
  • Ensures Quality products and processes are maintained by:
    • Understanding and supporting both quality policies and the Quality System while assisting with customer quality audits as needed.
    • Performing work at a level that ensures quality of this positions work meets or exceeds internal and external customer specifications.
    • Identifying and correcting if possible any identified quality issues both in the department and plant as a whole.
  • Actively participates as a leader in continuous improvement and cost-out efforts by:
    • Identifying and addressing any opportunities to reduce cost, improve product/process and/or improve overall operations
    • Participating and leading teams to eliminate problems, streamline operations or other areas as defined by management
    • Participating and leading training and exercises designed to expand the potential for continuous improvement.
Non-Essential Job Duties: Performs other duties that may be assigned.

Job Qualifications, Equipment and/or Experience:
  • Demonstrated capability to lead cross functional work teams in the implementation of process improvements that yield bottom line results.
  • Experience in the implementation of statistical process control and/or lean manufacturing principles within a fast paced manufacturing environment.
  • 7+ years in a Process Engineering role in a manufacturing environment.
  • Engineering/Manufacturing Procedure & Work Instruction writing
  • Capable of learning and complying with FDA/GMP regulations and ISO/TS Audits. Experience in the implementation of Statistical Process Control within a manufacturing environment.
  • Lean, Six Sigma, 8D, Zero Defect, Kaizen, Kan Ban, Single Minute Exchange Die [SMED] background
Language Skills: Good English communication skills, both verbal and written

Education, Certificates, Licenses, Registrations:

Bachelor's Degree in Chemical Engineering, Mechanical Engineering, Packaging Engineering, Industrial Engineering or other related industrial technology

We offer a full complement of valuable Health, Wellness, and Welfare benefits which include:
  • PTO & 8 Company Holidays
  • Medical, Dental, and Vision.
  • Life and Disability.
  • 401(k) and Match.
  • Wellness Program including EAP.
  • Pay for Performance philosophy.
  • Medical benefits are effective on the first day of the month after being hired

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