Process Engineer

ITW•Newburyport, MA

37d•$90,000 - $110,000•Hybrid

About The Position

Illinois Tool Works Inc. (ITW) is a Fortune 200 global manufacturing leader. The ITW Specialty Films division manufactures and markets specialized coated and metallized films. The Process Engineer strengthens process capability and throughput across film manufacturing operations, focusing on safety, quality, yield, and cost. This role involves designing and refining standard operating conditions and process optimizations using statistical data analysis for continuous improvement projects and new product/process introductions. The position partners closely with Production, Quality, Maintenance, and R&D to implement robust controls and deliver measurable OEE and scrap improvements. This position will be based in Newburyport, MA, with support for the Bloomfield, CT facility, requiring approximately 30% travel.

Requirements

Bachelor’s degree in Chemical, Mechanical, Industrial, Materials/Polymer Engineering (or related).
3+ years in manufacturing/process engineering; plastics films/PVC/coating/lamination preferred.
Proficiency with PFMEA, Control Plans, Process Flows, SPC/DOE, and data analysis tools (e.g., Excel/BI).
Demonstrated CI mindset (Lean/Six Sigma tools) and hands-on troubleshooting ability.

Nice To Haves

Experience in web coating/lamination, and converting/winding.
Familiarity with ITW’s 80/20 and decentralized operating model.

Responsibilities

Own setup, centerlining, and optimization for film coating/embossing, and converting/winding; define and maintain standard operating conditions and process windows.
Create/maintain PFMEAs, Control Plans, Process Flows, and operation sheets; ensure line documentation and change control are current and effective.
Apply SPC/DOE/CPK and structured troubleshooting to stabilize gauge/thickness, adhesion, optics, roll build, and winding performance; reduce variability and scrap.
Lead equipment capability studies and improvements to dies/air rings/web handling/coating heads, including line condition tracking and centerline management.
Analyze OEE, downtime, scrap, and material variance; prioritize and execute Lean projects that improve yield, throughput, and cost.
Prepare dashboards/metrics and present findings to leadership; standardize gains through SOPs, visual controls, and layered audits.
Support capital justifications with data-driven ROI for tooling, web handling, coating/lamination, winding, and automation enhancements.
Plan and run structured line trials for new film structures, coatings, laminations, and resin/material changes; capture learnings into standard conditions.
Collaborate with R&D/Quality/Supply Chain to validate fitness-for-use, run DOE and capability checks, and ensure smooth ramp from pilot to production.
Implement preventive maintenance frameworks with Maintenance/CMMS to sustain capability and reduce chronic losses on critical assets.
Be a floor-forward engineer; work shoulder-to-shoulder with operators and techs to train, troubleshoot, and embed best practices and centerlines.
Partner with Quality on complaint response, root cause, and CAPA; with Supply Chain on resin/film inputs; and with all leaders to uphold safety and regulatory compliance.
Communicate clearly at shift handoffs; ensure documentation, work notes, and action registers are current, visible, and closed out on time.
Provide Customer-Back suggestions to improve quality, reduce scrap, and increase first-pass yield.