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Extrusion Process Engineer

2 months ago

Pleasant Prairie, Wisconsin, United States Spectrum Plastics Master Full time

Position Overview:
The Extrusion Process Engineer is tasked with the execution and implementation of high-impact projects aimed at enhancing productivity and reducing costs within the organization.

Key Responsibilities:
- Analyze and resolve critical operational issues as assigned by the facility.
- Provide technical support for complex extrusion processes and assist production area technicians.
- Develop and assess products, materials, processes, or equipment to ensure optimal performance.

- Compile, analyze, and report operational, testing, and research data to set performance benchmarks for newly designed or modified products and processes.

- Collaborate with engineers, technicians, and operators throughout project development phases.
- Actively participate in hands-on operations to refine processes and develop procedures.

- Lead product development initiatives, including the construction, testing, documentation, and evaluation of prototype products for production readiness.

- Oversee process development activities such as Design of Experiments (DOEs), tooling qualifications, and validations for both processes and products.

- Serve as a project leader by implementing and maintaining Development Transfer Control Files for each project, which includes planning timelines, documenting processes, and conducting meetings and design reviews.

- Train production staff on new processes and product assembly techniques.
- Establish specifications and requirements for the design of new tooling, fixtures, and equipment.

- Research and procure materials necessary for project completion, utilizing detailed drawings, schematics, and instructions.

Customer Communication:
- Maintain communication with customers regarding project progress, concerns, and performance requirements.

Technical Expertise:
- Provide technical expertise for project development and troubleshooting, delivering innovative solutions to complex problems.
- Collaborate with Quality, Supplier Development, Manufacturing Operations, and Marketing teams.

- Act as the principal technical contact, ensuring the progression of concepts and technologies to support project commercialization throughout its lifecycle.

- Ensure alignment across various sites to harmonize operations and facilitate the transfer of knowledge, processes, technologies, and best practices.

Qualifications:
- Bachelor's degree in an engineering or scientific discipline.
- A minimum of 10 years of proven experience or an advanced degree with at least 8 years of relevant experience.
- Professional experience in medical device design and manufacturing technologies.

- Expert-level knowledge of integrated extrusion systems, test method development, and protocol execution.

- Experience mentoring junior technical staff members.
- Familiarity with GMP and ISO 9000 standards.
- Proficient in tooling design with advanced Solidworks CAD capabilities.

- In-depth knowledge of materials used in medical devices, including various polymers and their applications.

- Extensive understanding of polymer extrusion processes and equipment, particularly for medical applications.

- Project management experience related to new process, product, and technology development, ensuring successful transitions into manufacturing.

- Six Sigma Green Belt or equivalent certification is advantageous but not mandatory.
- Willingness to travel up to 10% of the time.

Competencies and Skills:
- Self-motivated with hands-on skills to simplify complex processes.
- Professional experience in exploring new technological opportunities.
- Ability to drive change and foster inter-organizational skill exchange.
- Excellent communication and interpersonal skills, capable of influencing all levels of the organization and clients.
- Strong problem-solving, organizational, analytical, and critical thinking abilities, demonstrating high discretion in decision-making.