Position SummaryWork Location: Saddle Brook, NJ(On-site)
We are seeking a data-driven, hands-on Process Engineer to aggressively drive On-Time Delivery (OTD) by optimizing machine utilization and reducing downtime. In this role, you will be part of team behind transforming our asset efficiency. You will identify underutilized or single-function equipment, engineer multi-functional tool-up solutions so machines can handle broader wire/cable product mixes, and execute time-studies to slash setup times. Our team is exploring new technologies (e.g., self-centering tooling, advanced quick-change fixtures), but we need an engineer who will dig into the shop floor, analyze our raw setup/run data, and precisely justify those investments to maximize machine runtime.
Core Responsibilities & Focus Areas1. Machine Utilization & Multi-Functional Tooling (Asset Efficiency)
- Asset Auditing: Audit and continuously track machine utilization across the floor; proactively identify and flag equipment that sits idle or is bottlenecked by single-function limitations.
- Cross-Functional Re-Tooling: Design, source, and implement mechanical modifications and tooling kits to adapt single-purpose machines into multi-functional work centers capable of running multiple cable configurations.
- Capacity Expansion: Strategically "tool up" auxiliary or under-utilized machinery to ensure a balanced, agile production floor with maximized total running hours.
2. Setup Time Reduction (SMED) & Time Studies
- Time Study Analysis: Conduct structured time and motion studies on the shop floor to cleanly isolate machine setup/changeover time from actual production run time.
- Targeted SMED Execution: Lead Single-Minute Exchange of Die (SMED) initiatives to re-engineer an existing 45-minute setup process down to a target of 25 minutes or less.
- Technology Evaluation & Justification: Evaluate make recommendations to our Director of Operation to build capital expenditure (CapEx) business cases for quick-change innovations, such as self-centering tooling, magnetic or pneumatic locking mechanisms, and modular guiding blocks.
- Standard Work Creation: Establish clear, visual standard operating procedures (SOPs) for changeovers to eliminate variance between operators and shifts.
3. AS9100 Compliance & On-Time Delivery (OTD)
- Rigorous Change Control: Ensure all machine modifications, new tooling implementations, and process parameter shifts strictly adhere to AS9100 configuration controls.
- Validation & Documentation: Author and execute validation protocols for any newly introduced tooling or quick-change equipment; support when process changes impact product geometry.
- OTD Driven Engineering: Align line balancing and machine availability improvements directly with the plant's weekly shipping schedules to eradicate production delays.
Required Qualifications & Skills
- Education: Bachelor's Degree in Mechanical Engineering, Industrial Engineering, Manufacturing Engineering, or a closely related technical field.
- Experience: 3-5+ years of process/manufacturing engineering experience, ideally within a continuous processing environment (e.g., wire and cable extrusion, braiding, stranding, or cabling).
- Lean Expertise: Proven track record of successfully executing SMED projects and time-studies that resulted in measurable downtime reduction.
- Technical Acumen: High proficiency in analyzing mechanical constraints and deploying advanced tooling solutions (e.g., self-centering systems, modular fixturing).
- Quality Systems: Solid understanding of working under AS9100 / ISO 9001 quality management systems, including formal root cause analysis (8D, RCCA) and engineering change notices (ECN).
- Soft Skills: A "dig-in" personality who prefers spending time on the production floor working alongside operators over sitting exclusively at a desk
Additional Skills & Qualifications:
- Bachelor's degree in Industrial, Manufacturing Engineering or other related Engineering discipline.
- Knowledge of Lean Manufacturing
- Strong interpersonal and communication skills
- Team first attitude w/the ability to work & produce results independently
- Self-starter with ability to effectively utilize resources to solve problems
- Strong data analysis skills
- Strong Microsoft Office skills with heavy utilization of advanced Excel tools.
Following receipt of a conditional offer of employment, candidates will be required to complete additional job-related screening processes as permitted or required by applicable law.
