Description
The R&D Process Engineer (plant focused) is responsible for developing, analyzing, and implementing new or modified process technologies, products, equipment, and systems for all plant manufacturing processes under the guidance of the plant leadership team. This position provides leadership in problem solving and supports production personnel to improve quality and productivity while aiming to reduce operating costs. The R&D Process Engineer implements process improvements and controls to reduce defects, scrap, rework, and downtime in production. Developmental work is coordinated with all necessary departments and is performed in accordance with acceptable and customary manufacturing practices while utilizing quality improvement techniques and experimental designs.
Duties and Responsibilities:
- Process improvement - Uses process data (defect, scrap, rework, OEE, etc.) to identify process
weaknesses and develops process methods, materials, training, and equipment modifications to
obtain improvement. Various quality methods are utilized, as is the bar code information
Participation and leadership of task groups is required. Interaction with production
personnel is an integral part of the improvement process. Support Carlisle Operating System
initiatives through training, participation in events, follow up and assisting with the training and
coaching of others. - Technical assistance to production personnel - Helps resolve problems relating to materials,
methods, and equipment. Develops and employs expertise in all areas of the plant
(compounding, extrusion, web handling, adhesive coating) Utilizes extensive knowledge and
experience with manufacturing processes to identify root causes and implement permanent
corrective measures. Coaches and teaches production personnel to assume "line ownership of quality" - Process control - Verifies and maintains control of production processes and variability through
the development, writing, issuing and revision of written process specifications. Implements and
trains pertinent positions in the use of statistical process control methods to identify factors
influencing process stability. Controlled factors include scrap, defects, rework, throughput rates, and dimensional characteristics as well as various aesthetic factors pertinent to customer - Project management/support - Assumes leadership and responsibility for various projects in the
plant including but not limited to: introduction of new technology and cost reduction; support and participation in the evaluation of R & D trials and experimentation for the development of new products, processes, and cost reduction; new product or process start-up, and the justification of new equipment or capital to improve processes. - Utilize Lean methodologies to participate in tiered accountability, development and tracking of site metrics for performance. Implement best practice layered audits of key equipment and define 3-year technical roadmap for the facility. Responsible to provide mentorship, guidance and analysis to team members and managers on projects and related technical issues.
- Development and maintenance of information systems. Responsible for maintenance/calibration of dimensional control systems, scrap/defect/rework tracking system and reports, mixing control system, and development/implementation of bar code system. Verify/report on/troubleshoot SAP information. Also responsible for various reports on projects and processes.
- Will be required to perform other duties as requested, directed, or assigned.
Required Knowledge/Skills/Abilities:
- Knowledge:
- Plastics manufacturing technology with an emphasis on sheeting products and web handling
- Compounding, powder blending, extrusion, windup equipment, and processing methods
- Testing for physical processing and chemical properties
- Plastic compounding and the interaction of raw materials in the compounding process
- Plant processing specifications, procedures, and grading standards
- Quality improvement/control methods including statistical process control, design of
experiments, gage R&R, and statistical data analysis - Commercial roofing application and installation
- Sheeting thickness control systems
- Company organizational structure and associated functions
- Production equipment operation including compounding equipment, powder mixing equipment, plastic extruders, extruder screw elements, gauge control systems, raw material feeders, unwind/winder equipment, and packaging equipment
- General knowledge of material handling equipment including feeders, blowers, and conveying systems
- Strong problem solving skills, and proficient with structured problem solving techniques such as DMAIC, Ishikawa, Five Why.
- Skills:
- Individual and team problem solving methods, including 5C and A3 methodologies
- Troubleshooting plastic sheeting manufacturing processes and procedures to find inefficiencies or problem areas
- Project management and facilitation
- Interpersonal skills including selling new concepts and ideas, listening, resolving conflicts, and considering alternate views to situations
- Abilities:
- Operating personal computers and software applications such as Microsoft Office, SAP, SFIS, and other process control systems
- Interpreting laboratory tests
- Communicating effectively with management, technical, and all other members of the plant
- Clearly and concisely writing technical/monthly reports to interpret data
- Effectively addressing small groups
Education and Experience:
- Required:
- Education: BS in Engineering or Science
- Experience: 5+ years of plastic/rubber processing or thermoplastics experience in a technical support role preferred
- Lean six sigma preferred
- #LI-LT1
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