Process Engineer

GENERA•Vonore, TN

20d•Onsite

About The Position

The Process Engineer is a hands-on engineering role supporting process development, equipment operation, sample production, troubleshooting, and continuous improvement in the Innovation Center (R&D Laboratory). The position serves as a primary technical resource for operating and optimizing pilot-scale and laboratory equipment used to develop molded fiber products, materials, coatings, and manufacturing processes. Responsibilities include planning and executing development trials, producing customer and internal samples, collecting and analyzing process data, and resolving process, material, and equipment issues. The Process Engineer works with Product Development, Operations, Quality, Maintenance, Sales, and external partners to evaluate technologies, develop scalable manufacturing solutions, and support commercialization. The role also periodically supports manufacturing operations through process optimization, production troubleshooting, continuous improvement, plant trials, and new product introductions, bridging R&D work with commercial manufacturing. A successful candidate combines engineering fundamentals, mechanical aptitude, hands-on equipment experience, analytical problem-solving, and the ability to work directly with laboratory and production personnel. The role requires working in office, laboratory, and industrial settings, and periodic travel between company facilities, suppliers, customer locations, and industry events.

Requirements

Bachelor's degree in Chemical Engineering, Mechanical Engineering, Manufacturing Engineering, Paper Science, Industrial Engineering, or a related technical discipline.
1–3 years of engineering experience in manufacturing, process engineering, R&D, a pilot plant, or an industrial environment.
Strong mechanical aptitude and problem-solving skills.
Ability to work safely in laboratory and manufacturing environments.
Understanding of process engineering fundamentals and manufacturing operations.
Knowledge of fluid systems, pumps, valves, vacuum systems, pneumatic systems, hydraulic systems, and process controls.
Ability to read and interpret engineering drawings, schematics, P&IDs, and technical specifications.
Familiarity with experimental design and statistical problem-solving techniques.
Proficiency with Microsoft Office, including Word, Excel, and PowerPoint, and data analysis tools.
Ability to independently operate laboratory and pilot-scale manufacturing equipment and troubleshoot equipment, reliability, and process issues.
Ability to diagnose product quality defects and process variation, including issues with material handling, forming, pressing, drying, trimming, and coating processes.
Strong verbal and written communication skills, analytical and organizational skills, and attention to detail.
Ability to manage multiple projects and priorities, work independently and in cross-functional teams, and maintain a positive, proactive approach to teamwork and continuous improvement.
Ability to stand, walk, bend, climb, and move throughout laboratory and manufacturing facilities; lift up to 50 pounds occasionally; and use required personal protective equipment.

Nice To Haves

Experience operating pilot-scale, laboratory, or manufacturing process equipment.
Experience in molded fiber, pulp and paper, packaging, converting, plastics, nonwovens, or related process industries.
Experience supporting product development, process development, or commercialization projects.
Experience with equipment troubleshooting and root cause analysis.
Familiarity with Lean Manufacturing, Six Sigma, statistical analysis, and process capability concepts.
Experience producing prototype or customer evaluation samples.
Experience supporting technology transfer from laboratory or pilot environments into commercial manufacturing.

Responsibilities

Operate, troubleshoot, optimize, and maintain pilot-scale and laboratory process equipment.
Produce customer, internal, and development samples for product development projects and commercial opportunities.
Plan, coordinate, and execute laboratory and pilot-scale trials, including rapid prototyping efforts.
Maintain safe and efficient operation of Innovation Center equipment and work areas.
Assist in developing processing parameters for new products, materials, coatings, and manufacturing technologies.
Record, analyze, and document trial conditions, process parameters, observations, and test results; prepare technical reports and recommendations.
Coordinate sample production schedules and support Innovation Center equipment setup, changeovers, cleaning, calibration, and maintenance.
Support laboratory organization, inventory management, and material handling.
Operate pilot plant and laboratory equipment for stock preparation, forming, pressing, drying, trimming, coating, testing, and related processes.
Troubleshoot equipment, process, material, and quality issues; identify root causes of process variation and implement corrective actions.
Monitor equipment performance, recommend improvements, and assist with installation, startup, commissioning, and qualification of new equipment.
Develop and maintain operating procedures, setup instructions, and troubleshooting guides; support preventive maintenance with Maintenance.
Evaluate equipment capability and recommend modifications or upgrades.
Support development of manufacturing processes, materials, products, and coatings, including Design of Experiments and process optimization activities.
Collect and analyze process, quality, and equipment performance data; identify critical process parameters and establish recommended operating conditions, centerlines, and operating standards.
Participate in material qualification, validation, and scale-up from laboratory trials to commercial manufacturing.
Document findings and communicate recommendations to technical and business stakeholders.
Provide engineering support to manufacturing facilities as business needs require, including troubleshooting process, quality, material, and equipment issues with Operations and Production.
Participate in root cause investigations and corrective actions; analyze manufacturing data for opportunities to improve safety, quality, throughput, yield, and cost.
Support continuous improvement using Lean Manufacturing, Six Sigma, and problem-solving methodologies.
Assist with process validation, startup, qualification, and plant trials for new products, materials, tooling, coatings, and manufacturing technologies.
Collaborate with Production, Maintenance, Quality, and Product Development to commercialize Innovation Center developments.
Monitor and improve manufacturing metrics including OEE, scrap, yield, throughput, and process capability.
Serve as a technical resource to operators, supervisors, and maintenance personnel during troubleshooting and improvement activities.
Comply with Safety and GMP requirements; use required personal protective equipment.
Develop and write Standard Operating Procedures or Work Instructions, document and track process changes, and present findings to local plant leadership or peers.
Travel periodically between company facilities, suppliers, customer locations, and industry events.