Job Summary

The RD&E Senior Process Engineer is responsible for training the process team staff and providing hands-on advanced level process troubleshooting. This involves using scientific tools/approaches to investigate, develop, and document the process parameters. This role will identify areas of improvement, implement process improvement efforts, and suggest design changes that could increase the overall process windows for transfer to production.

Essential Job Responsibilities

To perform this job successfully, an individual must be able to perform each essential functions/duty satisfactorily. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions. Other duties/functions may be added or assigned.

Operations

• Provides expertise in developing and refining thermoforming processes, including scale-up from R&D or pilot stages to full production.
• Evaluates thermoforming tooling from the design concept to its performance, working with Engineering and Mold Shop to refine.
• Uses ability to solve complex problems, individually or in a team, related to process deviations, equipment malfunctions, or material inconsistencies.
• Performs process capability studies and root cause analysis for resolution of manufacturing and product development issues, and assists with implementation of corrective actions.
• Collaborates with product development team to align Process development with R&D goals.
• Runs experiments, collects Process data, analyzes results, and make recommendations based on findings. This requires a strong knowledge and understanding of SPC, CPK, DOE, FMEA and the overall ability to analyze data.
• Provides detailed technical guidance and training to thermoforming Machine Operators, Setup Mechanics , Set up Technicians and Process Technicians throughout the company.
• Maintains strong relationships with current and potential vendors to provide technical guidance in new equipment selection for new projects, equipment upgrades.
• Assists in the troubleshooting, repair, and preventive maintenance of all facility machinery.
• Provides full support / leads the Commercialization process with ability to work different hours or shifts with minimum of notice.
• Provides Process support to IPC facilities, with ability to travel if necessary, with short or no notice.

Safety

• Comply with the EH&S Policy and applicable regulatory and company EH&S rules and requirements.
• Report to supervision conditions or practices that are either unsafe or that may adversely impact the environment, to ensure prompt resolution of potential hazards.
• Attend scheduled EH&S training program.
• Actively support the organization’s efforts to meet or exceed EH&S goals and plans.
• Recommend improved EH&S practices.
• Practices safe work habits and follows general safety procedures such as proper lifting and bending, ergonomics, proper use of equipment and use of personal protection equipment (PPE).

Product Safety and Quality

• Follows Product Safety and Quality standards.
• Follows GMP’s in regard to food contact packaging as it pertains to the employee.
• Follows IPC product defense standards and complies with all SQF requirements.

Minimum Requirements (include education, experience, special skills, licenses and/or certifications required.) The list below represents the knowledge, skill, and/or ability required to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

• A minimum of 15 years progressive thermoforming experience, or a two-year technical degree with minimum of 10 years of progressive thermoforming experience. Engineering degree preferred.
• Must be able to manage multiple projects simultaneously and work under minimal supervision.
• Strong technical skills in thermoforming, tooling, materials, product design, and affiliated processes including secondary operations and automation.
• Ability to define problems, collect data, establish facts, and draw valid conclusions. Experience with Lean Six Sigma tools preferred.
• Ability to interpret an extensive variety of technical instructions in mathematical or diagram form and deal with several abstract and concrete variables. Understanding and application of statistical analysis required.
• High degree of mechanical aptitude required, including strong Mechanical High and Low voltage knowledge including PLC basic troubleshooting skills.