Process Engineer

Neograf Solutions - Lakewood, OH

Full-time - Mid Level

Lakewood, OH

Electrical Equipment, Appliance, and Component Manufacturing

About the position

NeoGraf, a leader in graphite solutions for over 140 years, is seeking an experienced Process Engineer to join our team in Lakewood, OH. This role is pivotal as we expand our capabilities in specialty polymer compounding, allowing us to offer our products in both polymer masterbatch form and fully formulated compounds. The Process Engineer will play a crucial role in integrating manufacturing processes, equipment design, product formulations, and procedures to enhance efficiencies, improve product quality, and optimize material yields. This is an exciting opportunity to contribute to a new strategy within the company and make a significant impact on its success. In this role, the Process Engineer will be responsible for designing and optimizing twin-screw extruder screws to accommodate various materials, setting up compounding processes, and executing process development experiments using design of experiments (DOE) methodology. The engineer will collaborate with colleagues across departments to plan and execute trials and scale-ups, identify cost-reducing improvements, and provide technical support to troubleshoot operational issues. Additionally, the Process Engineer will lead the transition from experimental to full-scale production volumes, ensuring that all processes comply with safety standards and regulations. The ideal candidate will have a strong background in process engineering within the polymer industry, particularly with twin-screw extrusion, and will be well-versed in other compounding techniques. They will also be a role model for implementing lean and six sigma best practices while promoting a culture of safety within the organization. This position requires a commitment to continuous improvement and the ability to foster a safe working environment for all team members.

Responsibilities

• Design and optimize screws for twin-screw extruders to accommodate different materials.
• Set up the compounding process, using side feeding and vacuum degassing features where necessary.
• Define and execute process development experiments using design of experiments (DOE) methodology, including data analysis and documentation.
• Coordinate with colleagues in purchasing, scheduling, manufacturing, and technical personnel to plan and execute trials and scale-ups.
• Identify, develop, and implement cost-reducing improvements to manufacturing processes.
• Identify and implement process and quality improvements in current processes.
• Provide technical support and troubleshoot problems in operations processes.
• Lead the transition from experimental to full-scale production volumes for all compounds at the facility, including coordinating and reporting on production trials.
• Utilize and operate a range of essential laboratory equipment to support the optimization of processing methods, including measurements of Melt Flow Index, Density, Bulk Density, and Pellets per Gram.
• Coordinate advanced analytical testing of samples produced in process and formulation studies.
• Support the Director of Operations with employee training on new equipment, processes, or procedures.
• Execute continuous improvement initiatives (prioritized by the management team) using Lean Six Sigma methodologies.
• Monitor and seek to improve equipment effectiveness of all plant processes.
• Ensure that safety, engineering, and proper ergonomics are designed into new or revised processes and equipment.
• Ensure all manufacturing processes comply with safety standards and regulations.
• Develop and implement safety protocols and procedures to minimize risk and ensure a safe working environment.
• Conduct regular safety audits and risk assessments to identify potential hazards and implement corrective actions.
• Lead safety training sessions for employees, focusing on safe equipment operation and handling of materials.
• Promote a culture of safety awareness and continuous improvement among all team members.
• Investigate and report any safety incidents and proactively prevent recurrence.
• Participate in safety meetings and contribute to the development of safety initiatives.

Requirements

• Minimum of a Bachelor's degree in Polymer Engineering, Polymer Science, Chemical Engineering, or a related field. A Master's degree is preferred.
• At least ten years of experience in process engineering, specifically with twin-screw extrusion processes for compounding polymeric materials.
• Working knowledge of other compounding techniques, including Banbury internal mixers, Farrel Continuous Mixers (FCM), and Buss Ko Kneaders.
• Experience in compounding a wide range of thermoplastic and reactive compounds.
• Familiarity with Lean & Six Sigma methodologies; Green Belt certification is highly desired.
• Comprehensive understanding of OSHA and other relevant safety regulations.
• Experience in developing and implementing safety protocols in a manufacturing setting.
• Strong analytical and problem-solving skills, with the ability to analyze complex data sets.
• Experience with laboratory equipment and testing methods for the QC of polymeric compounds.
• Proficiency in AutoCAD or similar engineering design software.
• Knowledge of PLC control systems and dust collection systems is highly desired.
• Exceptional mechanical and mathematical abilities.
• Excellent communication, organizational, and teamwork skills.
• Commitment to safety and high housekeeping standards.
• Ability to read, interpret, and analyze blueprints and schematics.
• Results-driven with the capacity to own projects from inception to completion.

Nice-to-haves

• Master's degree in a related field.
• Green Belt certification in Lean & Six Sigma methodologies.
• Knowledge of PLC control systems and dust collection systems.