Process Engineer II

Process Engineer II•Bolingbrook, IL

21d•Onsite

About The Position

The Process Engineer II, reporting to the Lead Process Engineer, is responsible for managing Process Engineering activities to improve Safety, Quality, Delivery, and Cost metrics. This role focuses on the sustainment and improvement of various manufacturing processes, particularly in EPOX, with the goal of transforming molding processes to a world-class level in a fast-paced, hands-on environment. The main function involves leading and participating in problem-solving projects related to COQ (Cost of Quality) for Epox Processes, conducting failure analysis and fatigue testing for molded products, and developing sustainable processing methods with a focus on mistake-proofing. The position also drives the advancement of processing techniques to support long-term growth and cost savings, oversees research and development of new manufacturing equipment, processes, and procedures, and ensures manufacturing processes are improved through technical accuracy and adherence to standards. Additionally, the role supports data collection systems for business intelligence and analytics, establishes process controls and critical characteristics, conducts process audits, mentors engineers, maintains department metrics, reviews reports, assists with new equipment installation, and collaborates with cross-functional teams. A strong understanding of thermoset polymers and methodical problem-solving using statistical analysis is essential. Basic project leadership skills are also required.

Requirements

Bachelor’s degree in Chemical/Mechanical Engineering, Plastics/Polymer Processing, or Materials with 3 to 5+ years of experience in the field of materials processing.
Strong understanding and experience executing Design of Experiments (DOE’s) and A/B testing.
Strong understanding of Polymer rheology and test methods such as DSC, TGA, DMA and physical testing.
Experience with failure analysis using standard techniques.
Computer proficient; confident with data analysis programs.
Strong Problem-solving skills with experience using root cause analysis techniques such as 8D, 5Why, PDCA, and A3.
Ability to mentor, motivate and develop less experienced colleagues.
Demonstrable experience with new product production integration and/or operational improvement projects.
Possess an excellent understanding of thermoset polymers, from macroscopic to microscopic levels to assist in new product development, feasibility studies and failure analysis.
Methodical approach for problem solving using Designed of Experiment, Gage R&R trials, A/B testing, and statistical analysis to drive sustainment and improvement efforts.
Basic project leadership, including, but not limited to scope, schedule, cost, risk, resource, and change management.
Establish, track and manage key performance metrics for project success.

Nice To Haves

Previous history with molding and characterizing two component liquid thermoset plastics, cast resin compounds and vacuum casting.
Experience with silicone molding is a plus.
Liquid gelation molding and ring line dispensing systems experience would be a plus but not a necessity.
Knowledge of fluid dispensing systems, or centralized material delivery systems monitored by a distributed control systems would be a plus.
Possess skills and understanding of CAD, Pro-E and polymer flow simulation software.
Experience running a simulation software and concepts of material flow and characterize the material for feeding the simulation software.
Six sigma, Red X, or other problem-solving certification or experience.
Experience working cross-functionally with all levels of the organization structure.
Polymer material rheology and flow simulation experience.

Responsibilities

Leading and/or actively participating in COQ (Quality) problem solving projects with Epox Processes.
Actively involved in failure analysis and fatigue testing for molded products.
Creating sustainable processing methods and striving for mistake proofing within dedicated workcells and as otherwise assigned.
Driving advancement of processing techniques to support the long-term vision of growth and cost savings.
Overseeing research and development of new manufacturing equipment/software, processes, policies, standard operating procedures and work instructions.
Improving manufacturing processes through review of all engineering deliverables for technical accuracy and adherence to engineering standards and project schedules.
Supporting and improving JDE/QMS/MES or any other future data collection system for continuously improving our business intelligence reporting and data analytics.
Establishing process controls for all processes and train appropriate personnel for optimum use of it.
Establishing critical characteristics for all processes and systems for monitoring those variables.
Developing and conducting process audits in association with Quality and molding departments.
Mentoring engineers and support staff to work to their full potential.
Maintaining department quality and performance metrics.
Reviewing and writing reports related to ongoing projects.
Assisting in the selection and installation of new equipment.
Communicating and collaborating with cross functional managers and departments.
Preparing and delivering Process Engineering-related presentations as required.
Assisting with Molding technology lab and drive the Molding Innovation Center to help G&W reach world class status.