Process Engineer

POSITION SUMMARY: The Process Engineer will lead, and support projects aimed at driving continuous process and product improvements for the Floyd, VA site. Leveraging engineering expertise, Six Sigma methodology, and Lean manufacturing techniques, the role will plan, develop, and implement solutions that enhance product quality, process capability, efficiency, reliability, safety, sustainability, and cost-effectiveness.

The position will collaborate with cross-functional teams to identify and execute improvement opportunities, while fostering best practices and knowledge sharing. The role requires adaptability to evolving priorities, strong problem-solving skills, and the ability to deliver measurable results.

DUTIES AND RESPONSIBILITIES:

Executes on process improvements in batch, melting, fiberization, collection and packaging operations as identified, using project management methodologies and cross functional collaboration

Evaluates, initiates and leads various projects targeting process energy savings and environmental sustainability

Recommends modifications to processes and systems to address and correct deficiencies or variances

Develops process control plans that result in higher Cpk values on products

Studies existing process capabilities and directs improvement projects which support customer needs and business goals

Develops an understanding of customer requirements and promotes partnering relationships and data sharing that would establish cause and effect (if any) between fiber and media properties

Identifies capital and non-capital needs for process improvement, aiding in their design and implementation. Includes the initiation of CAPEX requests and effective management of the respective FEL process

Develops, evaluates and improves manufacturing methods and standards

Applies statistical techniques and lean principles to every day data collection, analysis and report-outs

Recommends process specifications for all equipment and systems. Coordinates process audits of deviations, and uses the information for specification development, process and equipment changes, and training

Tracks and reports on manufacturing performance

Observes and inspects conditions of processes and the fibers resultant physical property attributes to ensure compliance with quality standards

Confers with production to optimize process and product changes and analyzes and assists in planning work force utilization, space requirements, workflow and the layout of equipment and workspace for maximum efficiency

Partners with R&D to maximize process/product opportunities and executes, as site production representative, on production trials

Confers with management, engineering and other staff regarding manufacturing capabilities, production schedules and other considerations to facilitate production processes

Develops and provides problem-solving process training to manufacturing employees as needed

Assists the Operations Site Leadership to ensure a consistently high standard of housekeeping within the mill and/or areas of responsibility

Assists in the identification/resolution of non-conforming product and complaints

Follows all site safety requirements and assists in the identification and development of safety programs and investigations

EDUCATION/EXPERIENCE:

BS degree or higher in Chemical Engineering, Mechanical Engineering, Chemistry, or other technical discipline

3+ years of experience designing and optimizing manufacturing processes preferably in a continuous, nonwovens, or rolled goods manufacturing process

SPECIFIC KNOWLEDGE, SKILLS, LICENSES, CERTIFICATIONS, ETC:

Flexible, self-motivated, and team oriented

Plastics extrusion (meltblown or spunbond) experience preferred

Hands-on technical approach with operating teams, maintenance, and R&D

Data driven with experience in basic statistics and statistical process control

Familiarity with instrumentation and controls associated with manufacturing processes

Lean, six-sigma experience

6S experience

Computer skills desirable, including Microsoft Excel, Word, Access, Minitab

Occasional domestic and international travel may be required to support corporate objectives.

PHYSICAL DEMANDS AND WORK ENVIRONMENT:

The physical demands and work environment characteristics described here are representative of those that must be met by an employee to successfully perform the essential functions of the job.

Physical Demands: While performing duties of this job, the employee is often required to stand, walk, sit, talk, use hands to lift, carry, handle or feel objects, tools or controls; reach with hands and arms; balance, stoop. The employee is often required to lift up to 50 pounds. Specific vision abilities include close vision, distance vision, color vision, peripheral vision, depth perception and the ability to adjust focus. Occasionally required to climb stairs, kneel or crouch, balance.

Work Environment: Regularly exposed to hot and/or humid conditions in warmer months; wet and/or slippery areas, fumes or airborne particles, toxic or caustic chemicals. Work near moving and/or vibrating mechanical parts. The noise level ranges from quiet conditions to very loud noise requiring hearing PPE in some areas.