Sr Process Engineer

Morgan Hill, CA

Posted: 04/15/2019 Employment Type: Direct Hire Industry: IT Job Number: JOS000008594


The Senior Process Engineer will provide technical ownership for a family of production process lines, as a critical member of the thermoplastics operational team that is preparing for substantial growth. The senior engineer will be responsible for all technical aspects of continuous production processes, covering multiple product variants, to ensure maximum up-time, with highest efficiency and excellent quality. Additionally, the senior engineer will provide guidance and experienced direction across production support tasks, new product development, equipment installation and commissioning and production integration efforts.   

Primary Objectives & Responsibilities of the Position:  

This is an experienced, senior level, process engineering role, working as part of a small team of engineers. The role will require a high level of professionalism, impeccable communication, ingenuity, flexibility and problem-solving capabilities. A primary objective is to maintain and improve the consistency of the existing production processes, recommend updates to process control, monitoring and to pioneer equipment/technology/process and material upgrades to drive improved efficiencies and cost reductions while maintaining quality.  

The senior engineer will bring valuable Aerospace, or similar industry experience, along with Carbon Composite working knowledge. They will become very intimate with the methodology and techniques to produce continuous reinforced advanced thermoplastic composite materials, and will work throughout the value-chain of the product family, from Suppliers through to end customers to drive value-added engineering focused activities.  

The senior process engineer will also:  

  • Provide best in class process engineering knowledge and bring a depth of engineering and technological experience on how to fully productionize a process manufacturing facility that is poised for significant growth.  
  • Create concise, accurate manufacturing configurations, bills of materials, routers, work instructions. These will be compliant to the QMS system, either ISO 9001 and/or AS9100. Lead the effort to increase efficacy of shop work instructions and methods by employing industry best practices.  
  • Take a leadership role in establishing and measuring process performance capability using a digital toolkit to instill rigorous process control techniques, real-time. Using SPC methods, control plans, and other statistical, data-driven tools, the engineer will continuously optimize the overall process capability of all thermoplastic processing lines.  
  • Support effective team-work and sharing of engineering best-practice with a sister company team of engineers based in Europe.   
  • Recognize and troubleshoot problems associated with all aspects of unidirectional tape manufacturing processes and associated Quality Assurance processes.  
  • Prioritize and optimize all aspects of environmental health and safety with regards to the tooling, equipment, ergonomic practices and overall production processes.  
  • Develop clear, logical standard work processes in partnership with the production team, focused on safety, quality and cost control.  
  • Plan and executes capital projects and process improvement activities as business priorities demand. Manage the project budget and reporting framework to ensure goals and technical project objectives are met on time, within budget.  
  • Supports investigations and resolves operational non-conformances and customer or supplier related issues.   
  • Participate in customer site audits/qualifications and visits at the company; will represent the company in a professional manner.  
  • Successfully manage multiple projects.  
  • Assist as needed with training production associates, supervisors and managers on manufacturing processes.  
  • Be flexible in working hours if/when business needs dictate. Travel occasionally if necessary (US and Europe mainly) to support customer/supplier/internal projects and engineering activities.  

Qualifications & Education  

  • Minimum BS Degree (Mechanical, Manufacturing Aerospace, or Chemical) Engineering  
  • Master’s degree level preferred in relevant technical discipline  
  • Minimum 10 years of experience in a manufacturing or industrial setting.  
  • Practical application and substantial hands-on experience with improving process capability. Must be skilled in six sigma methods / SPC and lean manufacturing tools. Green or black belt six sigma credentials valued.  
  • IOT deployment within a process manufacturing experience desirable, with an emphasis on process control, feedback and optimization.  
  • Working experience of AS9100 quality management systems (or similar) essential.  
  • Minimum 3 year’s experience working with composite and/or plastic materials. Die design and extrusion process knowledge would be ideal.  
  • Experience with polymer extrusion processes desirable, in-particular PP, HDPE, PA6, PET, PC, ABS, PC/ABS materials.  
  • Able to design, set up and run Design of Experiments to understand key process input and output variability, concisely summarize engineering findings and then adjust/upgrade production processes accordingly.   
  • Product estimating experience, manufacturing costing understanding and compilation of RFQ proposals and development/capital project plans desirable.  
  • Able to steer procurement efforts and manage equipment suppliers, evaluate and select appropriate equipment and oversee its implementation and optimization, from conception through to full installation and production acceptance.  
  • PFMEA skillset, understanding of risk assessment or similar tools to evaluate material, method and process upgrades.  
  • Able to clearly write and compile detailed capital expenditure justifications for tooling, equipment and facilities level projects.  
  • Financially savvy – read and interpret operational and quality financial data and use effectively to steer modifications/upgrades to manufacturing performance.  
  • Extremely proficient in Excel and PowerPoint. Working knowledge of Minitab or similar software tools to analyze engineering data would be beneficial.  
  • PDM/PLM knowledge useful, ability to utilize CATIA or similar system a plus.  
  • Working knowledge of business ERP systems (Microsoft Dynamic AX® or similar).  
  • Able to develop and mentor junior engineers, displays openness to share knowledge and coach other employees.  
  • Leadership skills, or previous management experience would be beneficial.  
  • Continuous improvement bias, willing to challenge, and continually improve  
  • Excellent interpersonal, communication and organizational skills and the ability to work effectively in a cross-functional team, with all levels of the company.  
  • Energetic and takes initiative, accepts accountability and displays decisiveness, honesty and integrity 

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