Process Engineer PU

Process Engineer - Polyurethane Belting Manufacturing

The Process Engineer is responsible for daily support and strategic improvement of polyurethane mixing, dosing, heating, calendering, and curing processes used in the production of polyurethane belting. This includes but is not limited to developing and optimizing process parameters, maintaining technical process documentation, leading continuous improvement initiatives, troubleshooting manufacturing and quality issues, and managing capital equipment projects. The Engineer is the subject matter expert for polyurethane processing and has ownership over the manufacturing process. This position provides direction, coaching, and training to the Engineering, Maintenance, Production, and Quality Teams ensuring these resources effectively and efficiently support the facility such that safety, quality, delivery, and productivity standards are maintained.

Accountabilities:

* Maintains ownership of all polyurethane manufacturing processes to ensure safe, reliable, and efficient production of polyurethane belting that meets customer quality requirements.

* Develops, documents, and maintains process parameters and operating standards for polyurethane mixing, dosing, infrared heating, calendaring, cooling, and slab handling operations.

* Manage standards, formats, and filing of technical documentation including process specifications, equipment drawings, and standard operating procedures.

* Obtain, maintain, and share knowledge of polyurethane material behavior, additives, curing conditions, and product applications; apply knowledge to optimize product performance and manufacturability.

* Work closely with the Quality Team to monitor and improve product quality through process capability analysis, defect trend monitoring, and implementation of corrective and preventive actions.

* Lead root cause investigations for quality defects including surface defects, voids, open spots, dimensional inconsistencies, or mechanical performance issues.

* Develop and maintain process control strategies that reduce variability and ensure consistent product performance.

* Analyze manufacturing and quality data including temperature profiles, pressures, tensions, curing conditions, and throughput rates to identify opportunities for quality improvement and process optimization.

* Provide internal technical and product training as needed; including polyurethane processing fundamentals, equipment operation, troubleshooting, and best manufacturing practices across all applicable departments.

* Design and implement process improvements, tooling modifications, and auxiliary equipment solutions to improve safety, quality, and productivity of the manufacturing process.

* Provide the Maintenance Team with detailed instructions, process requirements, and BOMs for equipment modifications, repairs, and system upgrades; supporting reliability and optimizing OEE while ensuring safe operation and proper maintenance schedules.

* Support Procurement activities by maintaining contact with equipment suppliers, machine builders, and fabrication shops for quotation of components or assemblies related to polyurethane processing systems such as mixers, pumps, heaters, calendar systems, and conveying equipment.

* Maintain regular communication with counterparts at other global manufacturing locations; sharing best practices, troubleshooting strategies, process improvements, and quality standardization opportunities.

* Support or lead all local equipment-related CapEx projects; provide technical analysis in generation of business case, develop equipment specifications, establish FAT parameters with OEMs, support SAT, manage project schedules, collaborate with safety and quality departments in generation of all necessary preproduction documentation, and track performance against expectations.

* Draft and maintain current and future state internal plant layout drawings supporting efficient workflow, material movement, and process expansion; coordinate with third party engineering firms when necessary.

* Conduct continual improvement activities engineering out variation and developing robust manufacturing processes based on customer feedback and quality KPIs maintained by the Quality Team.

* Partner with Quality and Production to develop and implement inspection methods, process audits, and control plans that support consistent product quality.

* Ensures all safety procedures are followed by contractors and actively works to improve the plant safety program.

* Maintain and improve cleanliness, organization, visual management, and overall 5S to promote safe and efficient production.

* Takes leadership role in implementation of Lean Principles by applying the Ammega Production Process and actively working towards improvement, especially on assigned categories.

* Ensures all quality procedures are followed and actively works to strengthen the plant's quality management practices.

* Develops team members for future advancement through coaching, training, and mentorship.

* Other duties as assigned.

Requirements of the Job:

Bachelors degree in Mechanical, Chemical, Materials, Industrial, or Electrical Engineering, or an alternate Engineering degree with equivalent manufacturing experience will also be considered.

2-5 years of leadership experience in a manufacturing environment.

Experience with polymer processing, polyurethane systems, coating processes, calendaring, or similar continuous manufacturing processes preferred.

Experience with process control, quality systems, root cause analysis, and statistical process monitoring.

Experience working with process control systems, industrial sensors, PLC controlled equipment, and data analysis tools.

Computer experience (MS Word, Excel, PowerPoint, 365, etc.)

Knowledge and demonstrated success in applying Lean Manufacturing concepts (yellow belt or higher preferred)

Proven communication, analytical, and leadership skills.

Ability to solve complex process and quality problems and effectively teach highly technical information.

Excellent verbal, written, and interpersonal communication skills.

Must be able to work in the US.