The Process Engineer - Lamination is responsible for developing, optimizing, and sustaining lamination manufacturing processes to improve safety, quality, productivity, and cost performance. This position serves as the technical expert for fiberglass lamination operations, including material utilization, resin systems, tooling, work methods, and process controls. The Process Engineer works closely with Engineering, Production, Quality, Maintenance, and Supply Chain teams to reduce variation, eliminate waste, improve throughput, and ensure consistent product quality. This role leads continuous improvement initiatives, process validation activities, capital projects, and problem-solving efforts that drive operational excellence throughout the lamination department.
Essential Duties and Responsibilities:
- Serve as the primary technical resource for all lamination manufacturing processes.
- Develop, document, and maintain standardized work instructions and process specifications for fiberglass lamination operations.
- Analyze and improve lamination processes to enhance safety, quality, throughput, and efficiency.
- Monitor and improve key performance indicators including labor efficiency, material utilization, scrap, rework, first-pass yield, and overall process capability.
- Lead root cause analysis and corrective action activities related to lamination defects and process variation.
- Evaluate and implement improvements in resin application methods, reinforcement materials, tooling, consumables, and manufacturing techniques.
- Develop and validate new lamination processes, materials, and equipment.
- Support product launches by establishing manufacturing processes, labor standards, and quality controls.
- Lead Kaizen events and continuous improvement initiatives within the lamination department.
- Identify and implement opportunities for labor reduction, material savings, and cycle-time improvements.
- Partner with Quality to investigate defects, warranty concerns, and non-conformances.
- Work with Design Engineering to ensure products are optimized for manufacturability.
- Establish and maintain process control plans and standard operating procedures.
- Support CAPEX planning, equipment selection, and implementation of new manufacturing technologies.
- Train supervisors and production personnel on new processes, procedures, and best practices.
- Participate in safety initiatives and drive ergonomic improvements within the lamination area.
- Utilize data analysis and statistical methods to identify trends and support continuous improvement projects.
- Collaborate with Supply Chain and vendors to evaluate and qualify new materials and processes.
Qualifications: To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or ability required. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions.
Composite / Lamination Experience Preferred
- Knowledge of fiberglass reinforcement materials, resin systems, catalysts, gelcoat systems, core materials, and composite construction methods.
- Experience with hand layup, chop gun operations, resin infusion, vacuum bagging, closed-mold processes, and/or marine composite manufacturing.
- Understanding laminate schedules, resin-to-glass ratios, cure characteristics, material handling, and composite quality standards.
- Familiarity with common lamination defects such as porosity, dry glass, delamination, air entrapment, print-through, bridging, voids, and dimensional variation.
- Experience supporting marine, aerospace, automotive, or other composite manufacturing environments strongly preferred.
Other Qualifications:
- Proficient in Microsoft Office Suite with strong analytical and project management skills.
- Experience with Smartsheet, AutoCAD, SolidWorks, Rhino, Bambu Studio, and Mastercam preferred.
- Working knowledge of Lean Manufacturing, Six Sigma, Kaizen, standard work, visual management, and structured problem-solving methods preferred.
- Proven ability to lead Kaizen events, facilitate cross-functional teams, and implement continuous improvement initiatives that enhance safety, quality, productivity, and cost performance.
- Strong communication skills with the ability to work effectively with production employees, supervisors, managers, engineers, quality personnel, vendors, and leadership.
Education and/or Experience:
- 4-year degree in manufacturing, mechanical, or industrial engineering; 5 years related experience; or equivalent combination of education and experience.
Language Skills:
- Ability to read, analyze, and interpret general business periodicals, professional journals, or technical procedures
- Ability to write reports, business correspondence, and procedure manuals
- Ability to effectively present information and respond to questions from groups of managers, clients, customers
- Ability to lead cross-functional teams.
Mathematical Skills:
- Ability to perform calculations involving percentages, ratios, proportions, and basic statistical methods.
- Ability to analyze manufacturing, quality, and production data to identify trends, evaluate process performance, and support continuous improvement efforts.
- Ability to apply concepts of algebra and geometry to practical manufacturing applications.
Reasoning Ability: Ability to identify and analyze complex manufacturing, quality, material, and process-related issues within fiberglass lamination operations. Ability to collect and interpret production and quality data, determine root causes, evaluate alternatives, and implement effective solutions. Ability to apply engineering principles and sound judgment to improve process capability, eliminate waste, and support continuous improvement initiatives in a fast-paced manufacturing environment.
Physical Demands The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions.
Continuous/C = 67-100%, Frequent/F = 33-66%, Occasional/O = 33%, None/N
- Sits 3-6 hours
- Stands 4-6 hours
- Walks 3 hours
- Drives 0 hours
Employee Lifts and/or Carries:
Maximum: 40-50 lbs. (with assistance when required) Frequently: 10 lbs. Occasionally: 25 lbs.
Employee uses Hands for repetitive activities:
- Simple Grasping: Right- Constant Left- Constant
- Pushing/Pulling: Right- Frequent Left- Frequent
- Fine Manipulation: Right- Occasional Left- Occasional
Employee uses Feet for repetitive activities:
- Right: Occasional Left: Occasional
Employee is required to perform these activities:
- Bending at Waist: Frequent
- Squatting: Frequent
- Climbing Ladders, Stairs: Frequent
- Kneeling on Ground: Frequent
- Reaching Above Shoulder: Occasional
Work Environment The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job (i.e., heat/cold, dust/dampness, height; chemical; noise) PPE requirements are included. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions.
PPE: Safety glasses always required on Production floor. As required by task: hard hat, cut-resistant gloves, respiratory protection, other PPE as required.
Competencies
To perform the job successfully, an individual should demonstrate the following competencies:
Teamwork: Balances team and individual responsibilities; Exhibits objectivity and openness to others' views; Gives and welcomes feedback; Contributes to building a positive team spirit; Puts success of team above own interests; Supports everyone's efforts to succeed.
Motivation: Measures self against standard of excellence.
Quality: Demonstrates accuracy and thoroughness; Applies feedback to improve performance; Monitors own work to ensure quality.
Attendance/Punctuality: Is consistently at work and on time.
Dependability: Takes responsibility for own actions.
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