Senior Process Engineer

Job Title: Senior Plastic Extrusion Process Engineer

Location: Indiana

Employment Type: Full-Time

Experience Level: Senior (8-10 Years of Experience)

Job Summary:

We are seeking an experienced Senior Plastic Extrusion Process Engineer to join our dynamic manufacturing team. The ideal candidate will have 8-10 years of hands-on experience in plastic extrusion processes, a deep understanding of polymer materials, and a proven track record of optimizing production efficiency, quality, and safety. This role will involve leading process improvements, troubleshooting complex issues, and mentoring junior engineers while collaborating with cross-functional teams to drive innovation and operational excellence.

Key Responsibilities:

Design, develop, and optimize plastic extrusion processes, including single-screw and twin-screw extrusion, to meet production goals and quality standards.

Lead the selection, testing, and validation of polymer materials and additives for specific extrusion applications.

Analyze and troubleshoot process issues, identifying root causes and implementing corrective actions to minimize downtime and scrap rates.

Develop and maintain process documentation, including standard operating procedures (SOPs), work instructions, and process flow diagrams.

Collaborate with R&D, quality assurance, and production teams to support new product development and scale-up from prototype to full production.

Oversee equipment setup, calibration, and maintenance to ensure consistent performance and compliance with safety regulations.

Drive continuous improvement initiatives using Lean, Six Sigma, or similar methodologies to enhance efficiency, reduce waste, and lower costs.

Train and mentor junior engineers and technicians on extrusion techniques, equipment operation, and best practices.

Ensure compliance with industry standards, environmental regulations, and workplace safety protocols (e.g., OSHA, ISO).

Monitor key performance indicators (KPIs) such as cycle time, yield, and defect rates, providing regular reports to management.

Qualifications:

Bachelor’s degree in Mechanical Engineering, Chemical Engineering, Materials Science, or a related field (Master’s degree preferred).

8-10 years of direct experience in plastic extrusion process engineering within a manufacturing environment.

Expertise in polymer processing, including knowledge of thermoplastics (e.g., PVC, PE, PP, ABS) and their behavior during extrusion.

Proficiency with extrusion equipment, tooling design, and downstream processes (e.g., cooling, cutting, co-extrusion).

Strong analytical skills with experience in statistical process control (SPC), Design of Experiments (DOE), and root cause analysis.

Familiarity with CAD software (e.g., AutoCAD, SolidWorks) for designing extrusion dies or tooling is a plus.

Demonstrated leadership skills with experience mentoring teams or leading projects.

Excellent communication skills, both written and verbal, with the ability to collaborate across departments.

Certification in Lean Six Sigma (Green Belt or higher) is highly desirable.

Knowledge of regulatory standards such as ISO 9001, ISO 14001, or FDA requirements (if applicable).

Preferred Skills:

Experience with advanced extrusion technologies, such as multi-layer extrusion or profile extrusion.

Hands-on experience with automation systems and Industry 4.0 principles in manufacturing.

Ability to manage multiple projects in a fast-paced environment while meeting deadlines.

Benefits:

Competitive salary commensurate with experience.

Health, dental, and vision insurance.

401(k) with company match.

Paid time off and holidays.

Opportunities for professional development and career advancement.

Job Type: Full-time

Pay: $115,000.00 - $140,000.00 per year

Benefits:

401(k)

401(k) matching

Dental insurance

Health insurance

Paid time off

Vision insurance