Job Description

Description

PURPOSE:

The Senior Process Engineer (Plastics) will research, model, and develop manufacturing technologies, tool designs and processes for use in new and continuing programs for extrusion and injection molding applications. The candidate will also be responsible for executing critical design review processes as required for new product development as well as supporting ongoing production programs. Additional responsibilities include evaluating existing processes and configuring manufacturing systems to improve safety, increase on time delivery, improve quality, reduce manufacturing costs, increase productivity, and improve morale. This will also include the introduction and transition of new part number processes into mainstream production, in addition to, developing best practices within the manufacturing process while utilizing Lean Manufacturing methodology.

DUTIES / RESPONSIBILITIES: 

• Responsibility for the manufacturing technology & process development and troubleshooting
• Knowledge of engineered resin systems and related processes and tooling is highly desired. 
• Lead and support new product development process and transfer to production, supporting tool design and process development thru qualification. Perform calibrations as necessary.
• Coordinate with interdisciplinary engineering teams to infuse design for manufacturability
• Stay current on all types of manufacturing methods and tool designs.
• Investigate and recommend new technologies
• Manage current production and test equipment life cycles
• Ability to learn new processes and train employees

ESSENTIAL FUNCTIONS:

• Develop critical parameters for plastic extrusion and injection molding processes
• Develop, control and monitor extrusion formulations
• Analyze, develop and correct resin formulations to meet product specifications
• Participate in integrated product development teams addressing and solving manufacturing issues and related technical risks.
• Conduct design reviews and create written reports and deliver oral presentations (including preparation) as required.
• Lead the design, development, procurement and fabrication of tooling and production processes.
• Provide technical support to manufacturing such as process/tool evaluations; recommend specific equipment development needs, root cause analysis and implementation of corrective actions.
• Help to coordinate and support pre-production build activities.
• Provide technical support to manufacturing operations to resolve process problems and supplier issues relating to product performance and quality attainment.
• Lead efforts to reduce cost and improve manufacturing yields and throughput
• Facilitate and support PFMEA and Manufacturing Lean efforts.
• Initiate and/or review changes to engineering drawings or process documentation
• Create documented procedures relative to engineering and manufacturing processes as required.
• Proactively identify and immediately resolve manufacturing flow interruptions to eliminate production line stoppage
• Monitor production lines and identify areas for yield improvements utilizing SPC
• Identify and correct issues related to manufacturing Bill of Materials and process time standards
• Transform batch & queue processes to one-piece continuous flow lines and balance operations to Takt Time
• Research, Define, Evaluate, and Implement improvements to existing (legacy) products. Must be able to Define the problem, measure the improvement made in eliminating the problem, Analyze the problem, Improve and Control the process
• Plan and conduct experimental trials using current, modified, or new processes to eliminate production scrap or replace obsolete materials
• Plan, Define and Coordinate new product releases into Manufacturing. 
• Identify requirements and evaluate new processes through process capability studies to verify process parameters and make recommendations for implementation leading to innovative solutions
• Provide technical support to manufacturing, purchasing, production control, quality control/assurance to resolve issues
• Initiate the tool rework process by recognizing the need for tool rework, written documentation on what the tool rework will consist of, and the qualification of the tool after rework has been performed
• Develop, document, and communicate process methods and operator Standard Work Instructions
• Be able to communicate to all levels of the organization through written or verbal format when it comes to advice on incident investigation, corrective action, collecting, recording, and transcribing data, as well as showing results in various types of reports
• Research and purchase new manufacturing technology
• Schedule flexibility to support critical deadlines may be required. 

Requirements

EDUCATION AND/OR PROFESSIONAL LICENSE(s):

Bachelor of Science degree in Plastics Engineering, Materials Engineering, Mechanical or Industrial Engineering, Manufacturing Engineering or equivalent technical degree is required. Advanced Degree Preferred

EXPERIENCE: 

Preferred five to seven years of experience with hands-on plastic extrusion, injection molding, composites process and technology design, manufacturability analysis and experimental techniques. Experience working within an integrated product molding techniques and post molding secondary operations preferred. Previous experience with the development of manufacturing related documentation (MCPs, SWIs, BOMs, Labor Routings). Having prior experience in optics resin systems, dye packages or colorants is a plus. 

KNOWLEDGE, SKILLS, AND ABILITIES:

• A sound understanding of plastic extrusion and injection molding machinery, tooling, processes and materials
• Familiarity with new product development process and transfer to production
• Ability to read, analyze and interpret 3D models (SolidWorks preferred) and technical documents to support tooling, part, and subassembly reviews.
• Possess excellent written and oral communication skills as well as fluency in MS Office Products, Visio, Project, and statistical processing software such as MiniTab or similar knowledge is preferred.
• Working knowledge of Continuous Improvement methodology
• Proven ability to create, foster, and work in a team-oriented environment
• Develop and apply lean Six Sigma processes in design and manufacturing solutions.
• Possess and Provide examples of Root Cause Analysis and Problem-Solving skills
• A self-starter who is motivated to implement positive change on the manufacturing floor
• Must be organized and able to handle multiple tasks at one time
• High level participation in daily production activities and effective problem solving on daily issues
• Certification in the Six Sigma Process is preferred, having a working knowledge of the DMAIC process would be a plus

CONTACT WITH OTHERS:

This position requires contact and interaction with a multitude of technical disciplines within GENTEX Corporation, not only within the Carbondale facility, but with “sister” plants throughout the United States.

This position will also require interaction with GENTEX suppliers and occasionally with the customer.

PHYSICAL/MENTAL/COMMUNICATION REQUIREMENTS:

Employee is occasionally required to stand; walk; sit; use hands to finger, handle, or feel objects, tools, or controls; reach with hands and arms; climb stairs; balance; stoop, kneel, crouch, or crawl; talk or hear; and taste or smell. The employee may lift and/or move up to 50 lbs. Specific vision abilities required by the job may include close vision, distance vision, color vision, peripheral vision, depth perception, and the ability to adjust focus. The individual must have a high level of comprehension, and a high level of general, verbal, written, and numerical intelligence.

WORK ENVIRONMENT:

Works majority of the day in a climate-controlled environment, with the exception of, or otherwise specified, performing work in the warehouse or manufacturing areas which are subject to changes in temperature and/or noise.

TRAVEL:

Limited travel required

LOCATION: Gentex’s Carbondale facility is located in Northeastern Pennsylvania in Lackawanna County. Carbondale, PA is about twenty miles north of Scranton, PA, 50 miles south of Binghamton, NY, and about 125 miles from New York City and Philadelphia. The area hosts numerous nearby state parks, nature preserves and local colleges and universities, including The University of Scranton and Marywood University. Northeast Pennsylvania is a beautiful area and offers an excellent cost of living. It is a great place to work, recreate, meet people, raise a family and live!

Gentex Corporation is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard for any applicable state or federal protected class.  Gentex is an E-Verify Participant. Pre-employment drug/alcohol/background screening is required.