Hot Operations Process Engineer

Role Overview

We are seeking a skilled, driven, and hands-on Hot Operations Process Engineer to optimize and enhance manufacturing processes within the glass fiberization area. This position plays a critical role in supporting safe operations, improving process stability, maintaining product quality, reducing waste, and increasing equipment reliability.

The Hot Operations Process Engineer will serve as a technical resource for the production team, providing engineering support for daily operations while also leading longer-term process improvement initiatives. This individual will analyze manufacturing data, identify the root causes of performance issues, and implement sustainable solutions that improve safety, quality, efficiency, and profitability.

Success in this role requires a strong combination of technical expertise, mechanical aptitude, data analysis, and practical problem-solving. The ideal candidate will be comfortable working directly on the manufacturing floor, collaborating with hourly employees, supervisors, engineers, maintenance personnel, quality professionals, suppliers, and plant leadership.

This is an excellent opportunity for an experienced engineer who enjoys solving complex manufacturing challenges, leading improvement efforts, and making a measurable impact within a fast-paced industrial environment.

Key Responsibilities

Safety and Operational Support

• Identify, investigate, and address potential safety concerns within the glass fiberization area.

• Support the development and implementation of corrective actions designed to eliminate hazards and reduce operational risk.

• Promote a safety-first culture by incorporating safety considerations into all process changes, equipment modifications, and improvement initiatives.

• Participate in safety reviews, incident investigations, risk assessments, and operational audits as required.

• Ensure proposed process improvements comply with established environmental, health, and safety standards.

• Maintain a regular presence on the manufacturing floor to observe processes, engage with employees, and identify opportunities for improvement.

Process Improvement and Optimization

• Evaluate existing fiberization processes to identify inefficiencies, sources of waste, production constraints, and opportunities for cost reduction.

• Lead structured process improvement projects focused on increasing throughput, improving yield, reducing scrap, minimizing downtime, and enhancing overall profitability.

• Apply established continuous improvement methodologies to evaluate problems, determine root causes, and implement sustainable corrective actions.

• Develop project plans, define performance objectives, establish timelines, and monitor progress through completion.

• Evaluate the effectiveness of implemented changes and make additional adjustments when results do not meet established expectations.

• Identify opportunities to standardize successful processes, operating practices, and engineering solutions across the production area.

• Balance immediate production needs with long-term process improvements and reliability objectives.

Data Analysis and Process Control

• Collect, analyze, and organize manufacturing data to identify trends, variations, and sources of process inefficiency.

• Monitor and trend key performance indicators related to safety, quality, yield, waste, throughput, downtime, and process capability.

• Use statistical process control methods and software to evaluate process stability and identify abnormal operating conditions.

• Establish process limits, operating parameters, and control strategies that support consistent manufacturing performance.

• Develop dashboards, reports, and other analytical tools to communicate process performance and improvement opportunities.

• Ensure data used for decision-making is accurate, organized, and clearly documented.

• Translate complex operational data into practical recommendations for production employees and plant leadership.

Technical Leadership and Troubleshooting

• Serve as a technical expert for glass fiberization processes and related manufacturing equipment.

• Lead troubleshooting efforts involving process instability, product defects, equipment performance, production losses, and recurring operational issues.

• Conduct formal Root Cause Analysis investigations and facilitate cross-functional problem-solving sessions.

• Develop and implement corrective and preventive actions based on investigation findings.

• Provide technical guidance to supervisors, operators, maintenance employees, and other engineering personnel.

• Respond to urgent production concerns and support timely resolution of issues that affect safety, quality, delivery, or cost.

• Maintain technical knowledge of equipment capabilities, operating parameters, material properties, and process interactions.

Team and Project Leadership

• Lead small teams of hourly employees and cross-functional partners during process trials, equipment audits, and improvement projects.

• Coordinate process changes with production leadership to minimize disruption and ensure proper implementation.

• Engage employees who operate and maintain the equipment to gather practical feedback and strengthen proposed solutions.

• Provide clear instructions and expectations during trials, audits, and implementation activities.

• Support employee training when new processes, operating standards, or equipment changes are introduced.

• Build productive working relationships across production, maintenance, engineering, quality, and plant leadership.

• Demonstrate accountability for project results and communicate challenges, risks, and progress in a timely manner.

Equipment Reliability and Maintenance Partnership

• Collaborate closely with the Maintenance and Engineering teams to identify and address recurring equipment failures.

• Analyze downtime and maintenance data to identify failure patterns and reliability concerns.

• Support the development of preventive and predictive maintenance strategies for critical fiberization equipment.

• Recommend equipment modifications, replacement components, or maintenance practices that improve reliability and extend equipment life.

• Participate in equipment inspections, audits, commissioning activities, and post-maintenance evaluations.

• Assist in prioritizing reliability projects based on operational risk, production impact, and expected return.

• Ensure process requirements are considered during equipment repairs, upgrades, and capital improvement projects.

Quality and Product Performance

• Partner with Quality Engineers and production personnel to investigate product quality concerns and process-related defects.

• Analyze quality data to identify relationships between operating conditions, material performance, and finished-product results.

• Develop and implement targeted process improvements that enhance product consistency and customer satisfaction.

• Participate in quality investigations, corrective actions, and verification activities.

• Establish or refine operating standards that support consistent product quality.

• Support trials involving new materials, equipment, products, or manufacturing methods.

• Ensure process changes are properly validated before being incorporated into standard operations.

Supplier and External Partner Coordination

• Work with equipment manufacturers, material suppliers, and technical service providers to resolve performance and quality concerns.

• Communicate technical requirements and operational expectations clearly to outside partners.

• Evaluate proposed supplier solutions and determine whether they address the underlying operational need.

• Coordinate plant trials involving new equipment, materials, replacement components, or supplier recommendations.

• Document trial conditions, results, conclusions, and recommended next steps.

• Hold suppliers accountable for agreed-upon performance expectations and corrective actions.

Documentation, Reporting, and Compliance

• Develop, revise, and maintain ISO-controlled procedures, work instructions, process specifications, and technical documentation.

• Ensure documentation accurately reflects current operating practices and approved process requirements.

• Conduct or participate in internal ISO audits and support corrective actions resulting from audit findings.

• Maintain organized records of process changes, engineering trials, investigations, and improvement projects.

• Prepare clear and comprehensive technical reports detailing process performance, root-cause findings, project outcomes, and recommended actions.

• Develop and deliver formal presentations to plant leadership and cross-functional teams.

• Communicate process performance, risks, accomplishments, and improvement priorities to appropriate stakeholders.

• Support compliance with applicable company standards, quality systems, and regulatory requirements.

Qualifications and Requirements

Education

• Bachelor's degree in Mechanical Engineering, Chemical Engineering, or a closely related engineering discipline required.

Experience

• Minimum of five years of experience as a Process Engineer, Manufacturing Engineer, or in a comparable engineering role within a manufacturing environment.

• Experience supporting high-temperature, continuous-process, glass, fiber, chemical, or similar industrial manufacturing operations is strongly preferred.

• Demonstrated experience leading process improvement projects and implementing sustainable operational changes.

• Proven ability to troubleshoot complex manufacturing and equipment-performance issues.

• Experience working directly with production employees, supervisors, maintenance teams, and plant leadership.

Technical Skills

• Strong mechanical aptitude and a hands-on approach to troubleshooting and problem-solving.

• Advanced knowledge of formal Root Cause Analysis methods and corrective-action processes.

• Proficiency with statistical process control principles, tools, and software.

• Ability to collect, interpret, and communicate complex manufacturing data.

• Experience developing process controls, operating parameters, and performance metrics.

• Proficiency with Microsoft Office applications, including Excel, Word, PowerPoint, and Outlook.

• Experience using 3D modeling or computer-aided design software, such as SolidWorks.

• Ability to create and maintain technical procedures, controlled documents, specifications, and formal reports.

• Familiarity with ISO quality-management systems and internal auditing practices.

Leadership and Professional Skills

• Demonstrated leadership ability within a fast-paced manufacturing or industrial environment.

• Strong organizational skills with the ability to manage multiple priorities, projects, and deadlines.

• Data-driven and results-oriented approach to decision-making.

• Ability to lead cross-functional teams and influence others without relying solely on direct authority.

• Strong written and verbal communication skills.

• Ability to explain technical issues clearly to employees at all organizational levels.

• Sound judgment and the ability to make timely decisions in a production environment.

• Strong collaboration, relationship-building, and conflict-resolution skills.

• Self-motivated, accountable, and comfortable working independently.

• Commitment to safety, quality, operational excellence, and continuous improvement.

Work Environment and Physical Expectations

• This position requires frequent presence within an active manufacturing environment.

• The employee must be comfortable working near industrial equipment, elevated temperatures, noise, and other conditions commonly associated with glass manufacturing operations.

• Appropriate personal protective equipment must be worn as required.

• The role may require standing, walking, bending, climbing stairs, and observing equipment for extended periods.

• Occasional support outside normal business hours may be required to address urgent production or process concerns.

• Minimal travel is required.