Process Engineer

Rehau, Inc.•Cullman, AL

40d•$95,000 - $115,000

About The Position

REHAU is seeking an experienced Process Engineer to join our manufacturing team in Cullman, Alabama. In this role, you will be responsible for optimizing extrusion processes, driving continuous improvement initiatives, and ensuring quality, safety, and efficiency across operations. You'll collaborate closely with production, QA, maintenance, and R&D while also supporting new product development and equipment implementation. This position offers the opportunity to travel both domestically and internationally, including working with our technical team internationally and key suppliers.

Requirements

Strong knowledge of polymer materials and extrusion behavior.
Proficiency with extrusion equipment (extruders, dies, calibration tables, haul-offs).
Familiarity with PLC/SCADA systems and data analysis tools.
Understanding of rheology, heat transfer, and fluid dynamics.
Strong troubleshooting/root cause analysis.
Ability to interpret process data, charts, and SPC/DOE results.
Experience with FMEA and risk mitigation.
Ability to manage multiple projects and trials.
Skilled in cross-functional collaboration and communication.
Strong communication and interpersonal skills.
Detail-oriented, proactive, and able to work independently and in teams.
Bachelor's Degree in Chemical Engineering, Mechanical Engineering, Polymer Science & Engineering, Materials Engineering, or Industrial Engineering (with relevant experience).
5-10 years of professional experience in process engineering, extrusion, or related manufacturing fields.

Nice To Haves

Master's Degree in Polymer Engineering, Process Engineering, or Manufacturing Systems Engineering.
Coursework/experience in thermoplastics, extrusion, fluid mechanics, and heat transfer highly beneficial.
Certified Manufacturing Engineer (CMfgE) - SME
Six Sigma Green/Black Belt
Lean Manufacturing Certification
Extrusion Process Training (Polymer Center of Excellence, Penn College, SPE, etc.)
ISO 9001: Quality Management Systems
ISO 14001: Environmental Management Systems
OSHA Safety Training
PLC Programming & Automation Systems
SPC Tools
CAD/CAM or Simulation Software (SolidWorks, Moldflow, etc.)

Responsibilities

Process Optimization & Troubleshooting
Analyze and improve extrusion parameters to enhance throughput, reduce waste, and maintain product specifications.
Identify root causes of process deviations and defects; implement corrective and preventive actions.
Quality Assurance Support
Collaborate with QA to ensure products meet dimensional, mechanical, and visual standards.
Support SPC, capability studies, and quality audits.
New Equipment & Process Implementation
Lead installation, commissioning, and validation of new equipment, tooling, and auxiliary systems.
Develop and execute process qualification protocols and ensure smooth integration into operations.
Time Studies & Cost Analysis
Conduct time/motion studies to identify inefficiencies and optimize labor/machine utilization.
Perform cost calculations for material, cycle times, energy, and labor to support continuous improvement and investment decisions.
Documentation & Reporting
Maintain accurate records of process settings, trials, and metrics.
Prepare technical reports and presentations for management, audits, and cross-functional teams.
Continuous Improvement & Technology Integration
Lead/participate in Lean, Six Sigma, and Kaizen initiatives.
Support automation, sensors, and data acquisition systems for real-time monitoring/control.
Training & Support
Train operators and technicians on SOPs, troubleshooting, and best practices.
Provide technical support for daily operations and improvement projects.
Safety & Compliance
Ensure compliance with OSHA regulations, REHAU policies, and ISO standards.
Promote a strong culture of safety and environmental responsibility.