Process Engineer

Zotefoams

About The Position

The Process Engineer is responsible for planning, developing, improving, and implementing processes to enhance production efficiency, product quality, and equipment reliability. This role supports the integration of new technologies and continuous improvement initiatives across the production environment, working closely with Process Engineers to ensure seamless process alignment and optimization.

Requirements

Bachelor of Science degree in Engineering. Polymer Technology or Material Science discipline preferred.
Five (5) years or more related experience; background in sizable process-based industry. Process engineering experience within an extrusion environment is ideal. Cellular materials processing is a real plus.
Detailed understanding of polymer materials processing; extrusion specifically.
Understanding of materials testing methods, specifically polymer/foam testing.
Experience with process improvement techniques and quality tools such as SPC and capability measurement using Minitab/DOE/Quality Analyst to analyze and communicate outputs.
ERP systems experience desired. Microsoft Dynamics AX experience would be advantageous.
Lean/Six-Sigma techniques.
Proven excellent project management skills.
Excellent interpersonal, presentation and verbal/written communication skills, able to communicate effectively at all levels to facilitate the cross-fertilization of ideas and to influence decision makers.
Commercially aware with a creative, yet practical approach to problem solving, excellent judgment and a willingness to challenge current thinking.
Planning and organizational skills with the ability to lead, manage and motivate resources to maximize efficiency and effectiveness of processes.
Deadline oriented.
Data based problem solver.

Nice To Haves

Ideally candidate will have quality/process control experience.
Management experience of creative groups and experience of leadership in product development within an industrial environment is highly desirable.

Responsibilities

Lead the integration of new equipment, technologies, and manufacturing techniques into production with focus on project planning, ensuring smooth transition from pilot to full-scale implementation.
Develop and enforce safe, environmentally responsible working practices in accordance with company policies and regulatory standards.
Establish and monitor key performance indicators (KPIs) for manufacturing operations; analyze data to identify trends and implement corrective actions.
Collaborate with cross-functional teams including Engineering, Maintenance, Quality, Technical, and Projects to optimize equipment performance and process reliability.
Maintain effective communication across departments and external partners to support manufacturing goals and project execution.
Identify training needs and support employee development to align with manufacturing objectives.
Manage and execute projects focused on improving manufacturing processes, including extrusion, gassing, expansion, and fabrication.
Serve as project or team leader for manufacturing improvement initiatives.
Provide regular updates and reports to the Engineering Director and other stakeholders on project status and performance metrics.
Develop and maintain standardized operating procedures and process specifications; monitor compliance and address deviations.
Coordinate improvement activities with shift supervisors and production teams.
Act as a primary contact for production-related changes in materials, equipment, and processes.
Ensure alignment between product specifications and equipment capabilities using process data and quality metrics.
Support 24/7 manufacturing operations by providing real-time process control and troubleshooting support.
Organize and manage the integration of new equipment and techniques into the production environment and roll out from evaluation stage into full use across all machinery.
Maintain, enforce, develop and comply with safe and environmentally responsible working practices, in accordance with site procedures, and ensure that risk assessments are carried out prior to the use of any new substances, equipment or processes are appropriate.
Establish and monitor key performance indicators and implement continual improvement actions resulting from the analysis of performance data.
Liaise with engineering, other internal functions and external bodies as needed to modify/develop equipment and techniques to maximize effectiveness.
Facilitate the development and maintenance of good relationships with internal and external contacts and ensure clear and timely communication and to positively and actively contribute to all meetings where your knowledge or input is required.
Seek and undergo training and development as appropriate to meet the wider business objectives and needs.
Organize and progress projects for developing and improving the production process.
Act as a project/team leader as required.
Provide regular updates on work progress to the Engineering Director and others as required: providing written reports as appropriate.
Develop and implement standardized process running specifications and operating procedures for Extrusion, Gassing, Expansion and Fabrication.
Monitor adherence to and deviation of actual from standard. Take appropriate containment and corrective actions as necessary.
Coordinate formal improvement activity with the production managers and supervisors.
Coordinate processes related to extrusion/gassing/expansion/fabrication projects.
Act as the primary contact in all production related product or material development activity.
Ensure that product specifications and equipment capabilities are matched through the effective use of process data and product quality information.
Provide full and real-time process control of all raw materials and plant assets working with line and company functional management as needed in order that the department operates effectively 24/7 to the required OHSE standards.