Process Engineer - Operations

Role details

Responsible for monitoring, optimizing, and continuously improving Banbury mixing processes to ensure consistent product quality, operational efficiency, and process reliability. Utilizes data-driven analysis, process control techniques, and root cause investigation to identify opportunities for improvement, reduce variability, minimize waste, and lower manufacturing costs. Collaborates with production, quality, maintenance, and technical teams to implement process enhancements, standardize best practices, improve sustainability, and maximize overall plant performance and profitability.

Responsibilities

Monitor, maintain, and continuously improve Banbury mixing, milling, extrusion, and downstream manufacturing processes to ensure product quality, process consistency, and operational efficiency. Lead process optimization initiatives by analyzing process data, identifying sources of variation, and implementing sustainable corrective actions. Develop, validate, and maintain process parameters and operating windows for mixing, milling, extrusion, curing, and secondary manufacturing operations. Create and maintain manufacturing documentation, including process specifications, work instructions, standard operating procedures (SOPs), control plans, and data collection systems.

Ensure new compounds, formulations, and process changes are successfully transitioned into production through structured trials, validation, and operator training. Collaborate with Production, Quality, Maintenance, Technical, and Supply Chain teams to ensure manpower, equipment, materials, and process controls are prepared to support production requirements. Participate in new product introductions, process reviews, and manufacturing feasibility assessments to ensure robust and efficient production methods. Investigate process, quality, and productivity issues using structured problem-solving methodologies including Root Cause Analysis, 5 Whys, Fishbone Diagrams, Pareto Analysis, and 8D.

Lead and support continuous improvement projects focused on improving throughput, reducing waste and scrap, lowering energy consumption, enhancing safety, and increasing overall equipment effectiveness (OEE). Analyze manufacturing data and key performance indicators to identify improvement opportunities and support data-driven decision making. Participate in manufacturing layout, workflow, and material handling improvements to optimize plant operations. Support interactions with customers, suppliers, and equipment vendors as required to facilitate process improvements, trials, and project execution.

Develop and maintain process risk assessments, PFMEAs, control plans, audit systems, and other quality management documentation. Train operators, supervisors, and technical personnel on process standards, best practices, new equipment, and continuous improvement initiatives. Conduct process capability studies, production trials, and run-rate assessments to validate process performance and capacity. Ensure compliance with all Health, Safety, Environmental, Quality, and regulatory requirements. Support the organization's operational excellence objectives through active participation in Lean Manufacturing, Six Sigma, Energy Management, and Continuous Improvement programs.

Required Experience, Education, and Skills: Bachelor's Degree in Engineering, materials science, or equivalent combination of education and manufacturing experience. Minimum 3 years of experience in manufacturing, process engineering, rubber compounding, polymer processing, or a related industrial environment. Experience with Banbury mixing operations, rubber compounding, process control systems, and manufacturing process optimization preferred. Strong understanding of process capability, statistical analysis, process validation, and continuous improvement methodologies. Experience leading cross-functional projects from concept through implementation and sustainment.

Working knowledge of APQP, SPC, and structured problem-solving methodologies. Demonstrated ability to analyze manufacturing data and make decisions based on objective evidence and process performance metrics. Strong project management, organizational, and prioritization skills with the ability to manage multiple initiatives simultaneously. Excellent interpersonal, communication, and collaboration skills with the ability to work effectively across all levels of the organization. Proficiency in Microsoft Excel, data analysis tools, and manufacturing reporting systems. Knowledge of Lean Manufacturing, Six Sigma, and ISO 9001 principles is considered an asset. Other: Strong computer skills.

Project management and organizational skills. Proficient in Excel, Work, Power point. Proficiency in Minitab is an asset. Leadership and communication skills.