Senior Process Engineer

2 weeks ago

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

Location
PPC Pleasant Prairie

Role Summary

The Senior Process Engineer - Extrusion Technology is tasked with the execution and implementation of high-impact projects aimed at enhancing operational efficiency and reducing costs within the organization. This role involves analyzing and resolving critical operational challenges as designated by the facility. The engineer will provide technical assistance on complex issues to both extrusion process and production area technicians.

Key Responsibilities
  • Support engineers, technicians, and operators throughout project development phases.
  • Demonstrate the ability to operate processes and develop procedures as a hands-on contributor.
  • Lead product development initiatives by constructing, testing, documenting, and evaluating prototypes for potential production release.
  • Oversee process development activities including Design of Experiments (DOEs), tooling qualification, and process validations.
  • Act as a project leader by implementing and maintaining Development Transfer Control Files for each assigned project, which includes planning timelines, documenting processes, and conducting meetings and design reviews.
  • Provide training to production staff on new processes and product assembly techniques.
  • Develop specifications and requirements for the design of new tooling, fixtures, and equipment.
  • Research suppliers and procure necessary materials to facilitate project completion.
  • Work from detailed schematics, drawings, and verbal or written instructions.
  • Prepare and compile new operational and product quality procedures and specifications.
  • Maintain communication with clients regarding project progress, concerns, and product performance expectations.

Technical Expertise

• Offer technical expertise for project development and troubleshoot technical issues, providing innovative solutions.

• Collaborate with Quality Assurance, Supplier Development, Manufacturing Operations, and Marketing teams.

• Serve as the principal technical contact, responsible for advancing concepts and technologies to ensure expert knowledge throughout the project lifecycle.

• Ensure operational alignment across sites to facilitate knowledge transfer, process harmonization, and best practices.

Qualifications

• Bachelor's degree in an engineering or scientific discipline.

• A minimum of 10 years of relevant experience or an advanced degree with at least 8 years of experience.

• Proven experience in medical device design and manufacturing technologies or products.

• Expert-level experience with integrated extrusion systems, including test method development and protocol execution.

• Experience mentoring junior technical staff members.

• Training in Good Manufacturing Practices (GMP) and ISO 9000 standards.

• Proficiency in tooling design with advanced knowledge of Solidworks CAD.

• In-depth understanding of materials used in medical devices, including various polymers.

• Comprehensive knowledge of polymer extrusion processes and equipment.

• Project management experience related to new process, product, or technology development and successful manufacturing transfer.

• Six Sigma Green Belt or equivalent certification is advantageous but not mandatory.

• Willingness to travel up to 10%.

Skills and Competencies

• Self-motivated with hands-on skills to simplify complex processes.

• Professional experience in exploring new technological opportunities.

• Ability to drive change and promote inter-organizational skill exchange.

• Excellent communication and interpersonal skills, capable of engaging with all business levels and clients.

• Strong problem-solving, organizational, analytical, and critical thinking abilities, with sound judgment in decision-making.

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