Process Engineer, Powder

MP Materials Corp.•Fort Worth, TX

47d

About The Position

The Process Engineer, Powder will be an integral part of the team designing and building a new metal, alloy, and magnet-making facility. This is a rare opportunity to have a central role in the development of a greenfield advanced manufacturing facility and helping to define the future of American manufacturing. The ideal candidate will have hands- on experience in controlling metal powder production processes such as powder conveyance, hydrogen decrepitation, jet milling, classification, blending, quality control and other related powder processing techniques. The Process Engineer must be comfortable with equipment fault diagnosis, process development, PLCs, and P&ID. The new facility will contain a broad range of chemical, mechanical, and thermal processes, including electrowinning, strip casting, powder production, pressing & sintering, machining, and assembly. Because of the broad range of processes in use, it is important that the Process Engineer be able to engage with a broad range of technical specialists and gain a working understanding of the physical processes, key control metrics, and potential hazards involved. The key aspect of this role is to provide technical coordination and support to the powder processing operation to meet customer requirements.

Requirements

BS degree in Metallurgy/Materials Science, Mechanical, Chemical Engineering, Chemistry, or related field.
3-5 years' experience in metal powder processing with industrial scale processes and equipment.
Deep understanding of powder metallurgy processes for part manufacturing and powder quality control fundamentals such as particle size distribution (PSD), particle flowability, particle agglomeration, and more.
Knowledge and experience in gathering and tracking process control information for SPC.
Problem solving experience (FMEA, 8D, A3, Root Cause Analysis etc.).
Excellent written and verbal communication skills.
Experienced user of Microsoft Office suite.

Nice To Haves

5+ years of experience of industrial experience powder manufacturing, processing, and/or conducting powder metallurgy processes.
Deep technical knowledge of metal powder pulverization and hydrogen furnace operation.
Practical experience of the process safety associated with metal powder processing.
Experience with SAP.
Ability to identify and solve problems and convince others (management down to operators) that your solution is the right one.
Experience with programming, and process control operations; P&ID, PLC, CFD, MATLAB, Python, Mini -Tab, AutoCAD/Solidworks.

Responsibilities

Member of the Production Engineering team.
Work with production team members of upstream and downstream processes to execute the products for customers.
Work with procurement, vendors, maintenance, operators, and other team members on equipment specification, design reviews, and commissioning of new plant.
Contribute to EHS risk assessments, HAZOP studies, and regulatory compliance.
Plan, execute, and assist with process, and procedure development for hydrogen decrepitation (HD) furnace, Jet milling, dry grinding and powder blending.
Work closely with the NPI team in new process development and deployment in industrial scale.
Provide technical training and support to the production team and technicians on process knowledge.
Evaluate customer requirements and work in partnership with broader manufacturing and engineering teams to define process control plans to meet customer specifications.
Monitors and directs changes to key operating parameters under area of responsibility driving to achieve high yield, consistent product quality, and minimal EHS impacts.
Supervise the daily use of quality control procedures, driving initiatives to ensure stable and efficient powder processing operations.
Investigate and resolve equipment and quality issues within HD furnace, Jet Milling and subprocesses, working with QA, production, and customer service to address any product quality or customer complaints.
Document and disclose intellectual property and assist in patent filing preparation and defense.
Other duties, as assigned.