Process Engineer

Mactac North America•Troy, OH

13d•Onsite

About The Position

The Process Engineer provides technical assistance to plant operations at Mactac’s manufacturing facility in Troy, Ohio, supporting process improvement, cost reduction, safety enhancement, and efficiency. The role identifies and implements process changes to improve yields, reduce costs and downtime, increase runtime, and improve product quality. It involves complex projects with considerable impact on plant performance and costs. The Engineer is accountable for process performance of assigned assets, tracks OEE metrics, analyzes production data and gaps, and reports opportunities. The role works with production, maintenance, engineering, and technical personnel to troubleshoot issues, investigate root causes, establish operating standards, conduct process trials and validations, develop documentation and training, and lead projects for quality improvement and cost reduction. It also supports safety initiatives, capital project justifications, customer specifications, quality claims, raw-material processing changes, and operator preventative maintenance procedures. The position reports to the Director, Engineering. It is an individual-contributor role with no direct or indirect reports. The work is based at the Troy, Ohio manufacturing facility, with travel up to 5%. Approximately 20% of the time is spent in an office and 80% walking and working in the manufacturing area, where noise, odors, and other typical manufacturing environmental conditions may be present. Appropriate personal protective equipment is required and provided.

Requirements

Bachelor’s degree in Engineering.
At least 3 years of engineering experience in a manufacturing environment or related industry.
Ability and willingness to learn to operate equipment and repair or troubleshoot equipment alongside maintenance or technical staff.
Ability to confidently communicate findings, solutions, and status reports to management.
Proficiency with Microsoft Office software.
Strong judgment and decision-making ability, including identifying problems and pursuing risk-balanced solutions.
Strong problem-solving and analytical skills, including systematic analysis of problems and alternative solutions, and use of logic, mathematics, or other tools to analyze data or generate solutions.
Ability to communicate effectively in writing and verbally with stakeholders and people of varied educational and technical backgrounds, inside and outside the company.

Nice To Haves

Preference for a degree in Mechanical, Electrical, Industrial, or Chemical Engineering.
Additional education and/or training in Chemistry.
Working experience with Six Sigma, Lean Manufacturing, or a similar continuous improvement methodology; certification is strongly preferred.
Experience with converting film, paper webs, slot die, and/or curtain coating technology.
Prior CAD experience; highly preferred.
Experience with Enterprise Resource Planning (ERP) systems; experience with JD Edwards ERP is beneficial.

Responsibilities

Track overall process performance for assigned assets, including OEE metrics against goals; perform data and gap analyses and report major opportunities weekly.
Review production exceptions daily and work with production crews, team leaders, technical staff, and management to resolve issues and drive continuous improvement.
Identify, develop, and manage process-improvement projects focused on operational efficiency, waste, productivity, and costs, including developing and training required methods and procedures.
Reduce sources of variability related to safety, quality, delivery, and cost using the Rapid Problem-Solving Tool (RPS), continuous improvement initiatives, and standards or work instructions.
Troubleshoot production and process problems; communicate with relevant managers, supervisors, and operators; investigate root causes; and recommend and implement corrective actions.
Work with manufacturing and maintenance personnel to ensure equipment operates consistently under prescribed conditions and identify setup and run parameters, maintenance intervals, and material specifications.
Conduct trials to improve yields, reduce costs and downtime, improve runtime and quality, and scale up products.
Develop support, setup, run, and changeover documentation and facilitate training.
Write, perform, analyze, and report validations to support process standardization.
Develop project justifications and ROI analyses and prepare project or capital requests consistent with company policy.
Lead and manage assigned safety initiatives, keeping safety considerations paramount.
Assist Manufacturing in preparing standard operating conditions with input from operators, supervisors, and technical personnel.
Determine the need and justification for capital projects, including sourcing equipment and components, and complete and route capital allocation forms.
Assist Sales and Applications Development with customer specifications.
Investigate quality claims to determine root causes and develop and execute corrective actions to prevent recurrence.
Plan, execute, and document major changes to the processing of raw materials used in operations.
Assist Maintenance in creating and maintaining Operator Preventative Maintenance procedures for assigned assets.
Keep documentation accurate and current to reflect operating procedures.
Lead projects to implement changes that improve quality and reduce costs.