JOB SUMMARY
TekniPlex is hiring a Process Engineer for our Madison, WI facilities. This role applies engineering principles, team facilitation skills, and statistical process control tools to measure and improve key processes integral to the manufacturing of printed and unprinted laminated packaging materials for the pharmaceutical and medical device industries. Manages key process controls and develops relevant metrics to ensure process variables are quantified and remain within control. Manages small capital projects and cross-functional improvement teams to improve manufacturing costs and efficiencies while reducing process variability. The salary range for this role is $80,000 to $100,000 annually. Salary is based on experience.
DUTIES AND RESPONSIBILITIES
- Implement lean manufacturing principles. Facilitates cross functional improvement teams with the objective of implementing lean manufacturing principles.
- Identify, propose and execute projects to improve efficiency. Prepares proposals & reports and executes planned projects, including, determining time frames, funding, procedures for accomplishing projects, staffing requirements, and allotment of available resources to various phases of projects.
- Work directly with machine operators to identify needs and develop solutions; work with Maintenance on equipment modifications and preventative /predictive maintenance to ensure reliability.
- Identify, propose and execute projects to improve customer satisfaction, through performance and product reliability. Develops / improves product reliability, performance consistency and cost effectiveness.
- Provide manufacturing waste, Overall Equipment Effectiveness and other key operational reports to the site leadership team. Investigate issues and work to improve them.
- Develop thorough knowledge of all manufacturing processes and equipment; monitor and assess all equipment performance; develop requirements and participate in CER development for new/modified equipment.
- Assist or develop training and quality documentation.
- Statistically evaluate process parameters; assess impacts of material changes to efficiency and process integrity. Reduce scrap levels and increase yields.
- Develop strategies for process improvement and evaluate impact of such changes; actively participate in and/or drive root cause analysis and process improvement efforts.
- Be the plant liaison for trials and participate in all associated meetings and activities to ensure success.
- Evaluate and modify the Enterprise Resource Planning system and bill of material routers based on actual performance and the most efficient process workflow.
- Participate in customer complaint system with the goals of prevention of future occurrences and complaint avoidance.
- Promotes worker safety by:
- Actively assesses activities on a constant basis to ensure no unsafe actions or results will occur.
- Stressing safe working practices as a condition of employment to associates.
- Assisting in safety audits of employee behaviors to ensure compliance with safety rules and guidelines, as well as housekeeping audits and surveys.
- Participating actively on the plant-wide safety team.
- Ensuring the housekeeping in the immediate and surrounding work area is maintained or improved to the highest level possible.
- Ensures Quality products and processes are maintained by:
- Understanding and supporting both quality policies and the Quality System while assisting with customer quality audits as needed.
- Performing work at a level that ensures quality of this positions work meets or exceeds internal and external customer specifications.
- Identifying and correcting any identified quality issues both in the department and plant as a whole.
- Actively participates in the continuous improvement process (CIP) by:
- Identifying and addressing any opportunities to reduce cost, improve product/process and/or improve overall operations
- Participating in CIP teams to eliminate problems, streamline operations or other areas as defined by management
- Participating in CIP training and exercises designed to expand the potential for continuous improvement.
- Non-Essential Job Duties: Performs other duties that may be assigned.
REQUIRED QUALIFICATIONS
- Bachelor's degree in chemical, mechanical, or industrial or related engineering degree
- 3-5 years process experience, preferably in a manufacturing setting
- Demonstrated capability to lead cross functional work teams in the implementation of process improvements that yield bottom line results.
- Experience in the implementation of statistical process control and/or lean manufacturing principles within a fast-paced manufacturing environment.
- Engineering/Manufacturing Procedure & Work Instruction writing
- Capable of learning and complying with FDA/GMP regulations and ISO/TS Audits. Experience in the implementation of Statistical Process Control within a manufacturing environment.
- Lean, Six Sigma, 8D, Zero Defect, Kaizen, Kan Ban, Single Minute Exchange Die [SMED] background
- SQL database or programming experience is a plus
LANGUAGE SKILLS
Good English communication skills, both verbal and written. Ability to read and interpret documents such as safety rules, operating and maintenance instructions and procedure manuals. Ability to write routine reports and legibly complete timecards and work orders. Ability to read, analyze, and interpret technical procedures and read blueprints and technical drawings, such as machine, mechanical, pneumatic, hydraulic, and electrical. Ability to effectively present information in one-on-one and small groups situations to other employees of the organization. Ability to effective present information and respond to questions form groups of managers, clients, customers, and the general public.
MATHEMATICAL SKILLS
Ability to add, subtract, multiply and divide in all units of measure, using whole numbers, common fractions, and decimals. Ability to compute rate, ratio, and percent. Ability to apply concepts of basic algebra, geometry, fractions, percentages, ratios, and proportions to practical situations.
REASONING ABILITY
Ability to solve practical problems and deal with a variety of variable in situations where only limited standardization exists. Ability to interpret a variety of instructions furnished in written, oral, diagram, or schedule form. Ability to define problems, collect data, establish facts, and draw valid conclusions. Ability to interpret an extensive variety of technical instructions in mathematical or diagram form.
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 accommodations will be made to enable individuals with disabilities to perform the essential functions.
While performing the duties of this job, the employee is regularly required to stand, walk, and talk or hear. The employee frequently is required to use hands to finger, handle, or feel and reach with hands and arms. The employee is occasionally required to sit; climb or balance; stoop, kneel, crouch, or crawl; and taste or smell. The employee must regularly lift and/or move up to 10 pounds, frequently lift and/or move up to 50 pounds. Specific vision abilities required by this job include close vision, distance vision, color vision, peripheral vision, depth perception, and ability to adjust focus.
WORK ENVIRONMENT
While performing the duties of this job, the employee is frequently exposed to moving mechanical parts and vibration. The employee is occasionally exposed to high, precarious places; fumes or airborne particles; toxic, flammable or caustic chemicals; outside weather conditions; and extreme heat. The noise level in the work environment is usually moderate
The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job. Reasonable accommodations will be made to enable individuals with disabilities to perform the essential functions.
