Sr. Process Engineer- Molding

Position: Sr. Process Engineer (Molding)

Location: Etters, PA

RESPONSIBILITIES:

Function:

To conceive, plan, coordinate, develop, qualify and implement Standard & Molding process technology meeting our cost and capacity objectives against customer requirements. Responsibilities include all aspects related to the implementation (materials, tooling, equipment), operability and performance of new or existing Molding processes, their modifications and related documentation.

Engineering Tasks:

1. Coordinate project tasks and deadlines in maintaining project schedules and budgets. Solicit internal and external resource support to meet project timelines.

• Participate in definition of overall project plan and schedules for development projects in meeting time to market (TTM) objectives.
• Act as a consultant to management in assessing project aspects, feasibility and risks and in making technical recommendations for alternatives to achieve objectives against delivery schedules.
• Interface with vendors, quality, product engineering and manufacturing to assure capability and/or compliance in meeting process, product, delivery, and safety/environmental objectives.
• Coordinate equipment transfer and training of personnel for start-up facilities

2. Discovery & Definition focuses on early involvement with the product/process conceptualization to determine characteristics/requirements that meet product, manufacturing and customer objectives.

• Define processes inclusive of process specifications, setup sheets, control charts, operating procedures, spare parts lists and preventative maintenance plans.
• Provide input to define siting (facilities), area layout and infrastructure requirements.
• Define the process steps and sequence of operations, material handling and process control needs and to the extent possible, the preliminary process layout.
• Define process flexibility requirements based on proposed product configurations.
• Define the supply chain from raw material to customer application.
• Define the process step cycle times, efficiencies, yields and step relationships to include dynamic modeling as required for process and line balance assumptions. (Arrangement, Rates, Balance, Yield, Utility, Capacity)
• Product cost estimates inputs for each level of approach.
• Product/Process FMEA and risk assessment activities.
• Define critical product/process parameters.
• MoldFlow analysis to determine optimum fill pattern and resultant part deformation
• ProE product manipulation to simulate design variations in support of design for manufacturability (DFM) and High Volume Manufacturing (HVM)

3. Development focuses on deriving, characterizing and controlling specific techniques.

• Analysis of defined risk areas and experimentation, proof of principle tooling, feasibility studies, capability studies, detailed design and analysis, DOE, Passive data collection (PDC) and basic technology searches and development.
• Develop prototypes of specific tools and equipment to execute (and validate) a defined technique that would ultimately support manufacturing requirements.
• Develop and understand material processing behavior within specified processes or when subjected to a given technique. (both for FCI in-house and the end customer application)
• Characterize process for the purpose of identifying and eliminating variability (natural and special) so that process limits can be clearly identified and achieved.
• Characterize the behavior of materials within processes for the purpose of understanding variability and the establishment of controls through statistical practices.
• Qualify process criticals to required levels through product/process correction actions driven by root cause analysis that incorporate statistical practices.
• Identify process limits for product design to determine what is expected, day in and day out, under control and at defined levels of efficiency and profit.
• Maintain a base knowledge of key technologies.
• Share technologies and best practices throughout the company.

4. Deployment focuses on the transition and delivery to manufacturing.

• Interface with site management, quality, engineering, accounting, purchasing, materials management and other departments throughout all project phases in the procurement and transfer of processes.
• Deliver process specifications, setup sheets, control charts, inspection plans, operating procedures, spare parts lists and preventative maintenance plans.
• Transfer established best practices to the receiving site.
• Coordinate equipment transfer and training of basic personnel
• Provide training, guidance and support to production and specialized personnel.

5. Sustaining Engineering to extend product life cycle and offer product line extensions.

• Troubleshooting - Hands-on processing and mechanical maintenance. Understanding of electrical circuits a plus.
• Audits - Process, procedural and new trainings.
• Mold tool expansions.
• Succession planning, Product Line End-Of-Life assessments.
• Monitor production operations to Key Process Indicators (KPIs)
• Review and optimize spare parts supply chain.
• Maintain and update documents (JRA's, LOTO, process procedures, spare parts lists).

QUALIFICATIONS:

• Bachelor's degree (B. S.) from four-year college or university (preferably a degree in Plastics Engineering Technology) and 2 to 5 years' experience; or equivalent combination of education and experience
• Ability to develop prototype tools and processes to execute (and validate) a defined technique that would ultimately support manufacturing requirements and provide an understanding of material processing behavior within a specified processes or when subjected to a given technique.
• Ability to provide hands-on process development and troubleshooting of production tools and equipment.
• Proficiency with 3D/2D CAD tools such as CREO, NX, SolidWorks, AutoCAD, etc.
• Ability to characterize process and the behavior of materials for the purpose of identifying and eliminating variability (natural & special) so that process limits can be clearly identified and controls established through statistical practices.
• Ability to qualify process criticals to required levels through product/process correction actions driven by root cause analysis that incorporate statistical practices.
• Ability to read, analyze, and interpret professional journals, technical procedures or governmental regulations. Ability to write reports, business correspondence, and procedure manuals. Ability to effectively present information and respond to questions from managers, vendors, team members, and manufacturing site representatives.
• Demonstrated ability to operate with minimal supervision and provide updates on project status where issues or problems can be reviewed, discussed and resolved.
• Ability to communicate and relate well with engineers in each region of the world.
• Demonstrated skill and knowledge to train individuals and teams.

Should have knowledge and skills using:

• Microsoft Suite (Project, Excel, Word, Powerpoint)
• Geometric Dimensioning & Tolerancing
• Statistical analysis software (example JMP)
• Measurement System Analysis
• MoldFlow software
• Pro Engineer (preferable)