Process Engineer

Tekni-Plex - Madison, WI

Full-time

Madison, WI

Merchant Wholesalers, Nondurable Goods

About the position

The Process Engineer plays a crucial role in the manufacturing of printed and unprinted laminated and coated packaging materials specifically for the pharmaceutical and medical device industries. This position utilizes engineering principles, team facilitation skills, and statistical process control tools to measure and enhance key processes that are integral to production. The engineer is responsible for managing key process controls and developing relevant metrics to ensure that process variables are quantified and maintained within control limits. In addition to process management, the Process Engineer will oversee small capital projects and lead cross-functional improvement teams aimed at enhancing manufacturing costs, efficiencies, and reducing process variability. This role requires a hands-on approach, working directly with machine operators to identify needs and develop effective solutions, as well as collaborating with the maintenance team on equipment modifications and preventative/predictive maintenance to ensure operational reliability. The engineer will also be tasked with analyzing data to identify opportunities for efficiency improvements, preparing proposals and reports, and executing planned projects. This includes determining time frames, funding, procedures for accomplishing projects, staffing requirements, and resource allocation. Furthermore, the Process Engineer will develop strategies for process improvement, evaluate the impact of changes, and actively participate in root cause analysis and process improvement efforts. Safety is a paramount concern, and the Process Engineer will promote worker safety by continuously assessing activities to prevent unsafe actions and stressing safe working practices as a condition of employment. The role also involves providing key operational reports to the site leadership team, developing thorough knowledge of all manufacturing processes and equipment, and participating in customer complaint systems to prevent future occurrences.

Responsibilities

• Implement lean manufacturing principles.
• Facilitate cross-functional improvement teams to implement lean manufacturing principles.
• Analyze data to identify, propose, and execute projects to improve efficiency.
• Prepare proposals and reports and execute planned projects, including determining time frames, funding, procedures, staffing requirements, and resource allocation.
• Work directly with machine operators to identify needs and develop solutions; collaborate with Maintenance on equipment modifications and preventative/predictive maintenance.
• Identify, propose, and execute projects to improve customer satisfaction through performance and product reliability.
• Provide manufacturing waste, Overall Equipment Effectiveness, and other key operational reports to the site leadership team.
• Develop thorough knowledge of all manufacturing processes and equipment; monitor and assess all equipment performance.
• Statistically evaluate process parameters; assess impacts of material changes to efficiency and process integrity.
• Develop strategies for process improvement and evaluate the impact of such changes; participate in root cause analysis and process improvement efforts.
• Act as the plant liaison for trials and participate in all associated meetings and activities to ensure success.
• Support process monitoring and vision systems to assist Operations and Quality with defect identification.
• Evaluate and modify the Enterprise Resource Planning system and bill of material routers based on actual performance and efficient process workflow.
• Participate in the customer complaint system with the goal of preventing future occurrences and complaint avoidance.
• Promote worker safety by assessing activities to ensure no unsafe actions occur and assisting in safety audits.

Requirements

• Bachelor's degree in Engineering or a related field.
• Experience in manufacturing processes, particularly in the pharmaceutical or medical device industries.
• Strong analytical skills and experience with statistical process control tools.
• Proven ability to lead cross-functional teams and manage small capital projects.
• Excellent communication and interpersonal skills to work effectively with machine operators and maintenance teams.
• Knowledge of lean manufacturing principles and practices.

Nice-to-haves

• Experience with Enterprise Resource Planning (ERP) systems.
• Familiarity with safety audits and compliance in a manufacturing environment.
• Certification in Lean Six Sigma or similar methodologies.