Process Engineer in Alsip

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Job DescriptionJob Description

**ROLE OVERVIEW: **The Process Engineer applies knowledge of mechanical, hydraulic, pneumatic, and electrical controls, and PLC programming to support projects for the repair, upgrade, or replacement of facility equipment and controls in a plastic manufacturing environment (Blow Molding). The Process Engineer conducts process optimization trials, performs troubleshooting and analysis, and develops strategies to reduce product variability, waste, and operating costs. The position will work closely with Plant Managers, Process Technicians, and operators, providing training, standardized processes to optimize colleague safety, product quality and cost. Works on projects of large scope and complexity and resolves problems where precedent may not exist.

***The location for this position is Alsip, Illinois; however, the role may also be based in Houston, Texas. ***

Key Responsibilities

• Promote improvements on the production process through Kaizen, VSM, and other lean techniques in conjunction with OPEX, with emphasis on productivity gains, labor optimization, quality, seeking new methods or technologies, and replicating them in other plants.

• Prepares equipment and controls specifications and places orders. Evaluates existing equipment and controls with regard to productivity, cost-efficiency, and safety, and makes recommendations for possible improvements.

• Conducts process optimization trials, performs troubleshooting and analysis, and develops strategies to reduce product variability, waste, and operating costs.

• Apply root cause analysis and analytical problem-solving techniques to daily problems and/or misses.

• Maintains complete and accurate records of all work performed and prepares monthly quality and production reports.

• Lead training of plant operators and leaders on standard production execution, to assure colleague safety, product quality, and cost.

• Create, execute, and support process-related training materials for machine operators and maintenance teams.

• Ensure adherence to existing Standard Operating Conditions (SOC) & develop and track SOC for all major equipment with min/max ranges.

• Work collaboratively with site maintenance teams to establish a Critical Process Equipment (CPE) Program to ensure all CPE items are audited and well-maintained.

• Work with Reliability Engineer and Quality to deploy complete VQS on each equipment. Develop optimum process parameters to achieve desired quality and product certification performance requirements.

• Works with plants and develops programs to ensure optimal process parameters are maintained.

• Works with facilities to help achieve and maintain product certifications.

• Replicate lessons learned, standard practices, and increase the synergies across the substrate to have all plant colleagues at the same level.

• Contribute and work together with the Product Engineer to elaborate testing, prototypes, samples, or any other effort related to the production process to make new products.

• Work with the Reliability Engineer on equipment troubleshooting, documentation, and training for maintenance colleagues.

• Work with other engineering teams, with the common purpose of building a strong technical foundation at the plants.

• Work closely with OPEX and other support functions to drive A3 continuous improvement projects

Education and Experience

• Bachelor's degree (or equivalent) required

• 5+ years of experience in plastic blow molding is required.

Knowledge and Skills

• Strong mechanical skills, including knowledge of electrical, pneumatics, hydraulics, air compressors, chillers, and PLCs, with the ability to make required adjustments.

• Able to troubleshoot machine maintenance issues as they arise

• Demonstrated success in cycle time optimization and identifying cost savings

• Strengths in Lean Manufacturing & Continuous Improvement

• Strong understanding of plastics materials, manufacturing processes, and machinery operations.

• Strong attention to detail and commitment to quality assurance.

• Problem-solving skills: Capability to troubleshoot and resolve production issues.

• Good communication skills and ability to work effectively in a team environment.

• Adherence to safety protocols and regulations in a manufacturing setting.

• Ability to make process changes to ensure production of high-quality product.

• Ability to document work practices and communicate them to all colleagues.

• Strong working knowledge of Microsoft Office suite of applications.

• Ability and willingness to travel required!

Compensation Range:

The pay range for this position is $101,800.00 - $173,300.00. Typically, a competitive wage for new hires will fall between $125,000.00 to $135,000.00. Offers for this position may vary based on market data and other factors such as job-related knowledge, skills, experience, and geographic location. The position may also be eligible for a short-term incentive.

You should be proficient in:

• Mechanical Troubleshooting Skills
• Pneumatics Experience
• Process Engineering
• PLC Programming Experience
• Lean Manufacturing Principles
• Engineering Degree
• Plastic Extrusion Experience
• Blow Molding Experience

Machines & technologies you'll use:

• Extrusion Machine
• ERP Software
• Blow Molding Machine

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