POLYOLEFINS PRODUCT DEVELOPMENT ENGINEER

Role details

Company Overview for Formosa Plastics Corporation, U.S.A.

Founded in 1978, Formosa Plastics Corporation, U.S.A. (Formosa Plastics) is a growing, vertically-integrated supplier of plastic resins and petrochemicals. With annual revenues of more than $5 billion, we employ over 2,800 people who operate 20 production units in six business divisions - Olefins, Polyolefins, Vinyl, Specialty Polyvinyl Chloride, Chlor-Alkali, and Oil & Gas.

Formosa Plastics offers a full line of polyvinyl chloride, polyethylene and polypropylene resins, caustic soda and other petrochemicals that deliver the consistency, performance and quality that customers demand. We market our polypropylene and polyethylene resins under the Formolene® tradename; we market our suspension PVC and specialty (dispersion) PVC resins under the Formolon® tradename. We also produce and sell caustic soda, ethylene dichloride, commercial bleach and hydrochloric acid.

We are committed to supplying the highest quality products and services to our customers, providing a safe and healthy workplace for our employees and contributing to the quality of life in the communities where we operate. This commitment is made possible through our dedicated people, consistent products, continued protection of the environment and ongoing investments in new product development, quality control systems and safe, modern and energy-efficient production facilities.

Formosa Plastics is a privately held company headquartered in Livingston, New Jersey. Our core business, producing plastic resins and petrochemicals, takes place at three wholly-owned chemical manufacturing subsidiaries located in Delaware City, Delaware, Baton Rouge, Louisiana and Point Comfort, Texas.

I. POSITION OBJECTIVE

The primary objective of this role is to carry out R&D projects that drive significant profits or cost savings while creating value-added products. This involves developing new products, enhancing existing FPC resins and compounds, and effectively addressing customer product concerns. The product development engineer aims to strengthen the company's competitive edge; developing process and formulation optimization, and contributing to a more sustainable future for polyolefins. Additionally, it ensures a safe and healthy work environment, adhering to environmental, health, and safety regulations, as well as company standards.

II. MAJOR AREAS OF ACCOUNTABILITY

Product and Technology Development

Develop and deliver new and improved products, formulations, catalyst technologies, and technical solutions in a timely manner to generate value creation and/or cost savings. Improve the competitiveness of the product portfolio and product quality to meet customers' needs. Work closely with customers, Marketing, Operations, Quality, and R&D to identify opportunities, troubleshoot technical issues, and serve as a technical solution provider.

Operations and Technical Support

Provide technical support to Operating Units to enable safe, reliable, and efficient operation, manufacture high-quality products, and minimize unplanned process interruptions. Monitor process performance, investigate operating issues, provide recommendations, and work with Operations and Maintenance to implement sustainable solutions. Support process troubleshooting, optimization, start-ups, shutdowns, and abnormal operating conditions as required.

Process Improvement and Optimization

Study manufacturing processes and identify opportunities to improve productivity, yield, energy efficiency, throughput, reliability, quality, and operating cost. Utilize process data, benchmarking, best practices, statistical analysis, root cause analysis, and other appropriate engineering methodologies to identify and implement improvements that move the plant toward Best Industry Practice.

Product Quality and Quality Assurance

Monitor product quality trends and investigate deviations, customer complaints, and out-of-specification conditions. Identify root causes and develop corrective and preventive actions. Collaborate with Operations and Quality teams to improve process consistency, product specifications, and manufacturing capability while ensuring products meet internal, customer, and applicable regulatory requirements.

Customer Technical Service

Provide technical support to customers by understanding product performance requirements, investigating technical concerns, and developing practical solutions. Participate in customer visits, trials, product evaluations, and technical discussions. Translate customer requirements into actionable product or process improvements and communicate technical findings effectively to internal and external stakeholders.

Process Safety and Risk Management

Participate in Process Hazard Analyses (PHA), Management of Change (MOC), Pre-Startup Safety Reviews (PSSR), incident investigations, risk assessments, and other process safety activities. Identify potential hazards associated with process changes, new products, raw materials, equipment, and operating conditions and support implementation of appropriate safeguards and recommendations.

Troubleshooting and Root Cause Analysis

Lead or participate in investigations of recurring process, equipment, product quality, and customer-related problems. Apply structured problem-solving techniques such as Root Cause Analysis (RCA), 5-Why, Pareto analysis, statistical methods, and process modeling to determine underlying causes and develop sustainable corrective actions. Track actions through completion and verify effectiveness.

Manufacturing Cost and Value Creation

Identify opportunities to reduce manufacturing costs through improvements in raw material consumption, energy usage, yield, cycle time, waste generation, catalyst utilization, equipment performance, and process efficiency. Quantify potential and realized financial benefits and support the department's value-creation objectives.

Reliability and Asset Performance Support

Work with Operations and Maintenance to identify process conditions that contribute to equipment degradation, fouling, corrosion, plugging, vibration, or other reliability concerns. Provide technical input into reliability improvement initiatives, equipment modifications, maintenance strategies, and operating-window development.

Cross-Functional Collaboration

Work effectively with Operations, Maintenance, Engineering, Projects, Quality, Laboratory, Supply Chain, Procurement, Commercial, Sales/Marketing, HSE, and other technical functions to resolve problems and deliver business objectives. Communicate technical information clearly to both technical and non-technical

audiences.

Continuous Improvement and Innovation

Identify opportunities to improve technical work processes, engineering methods, manufacturing practices, and technology deployment. Encourage innovative approaches to recurring technical challenges and participate in continuous improvement programs that improve safety, quality, reliability, productivity, and cost competitiveness.

Professional Development and Technical Competency

Continuously develop engineering knowledge and technical competencies relevant to the plant's processes, products, equipment, technologies, and business objectives. Seek opportunities to expand expertise through training, mentoring, industry engagement, technical projects, and hands-on plant experience.

THM: Promote cleanliness and order through implementation of the Total Housekeeping Maintenance program. Emphasize Nothing Touch the Ground Program and No Visual Pollution Program. Maintain the plants’ like new condition.

III. QUALIFICATIONS

A. TECHNICAL JOB CRITERIA

• Previous Related Experience Required

(0 - 5) years of polymer experience, preferably in polyolefins with experience conducting research in a laboratory setting. A strong academic and practical background in chemical engineering, chemistry, chemical and instrumental analysis, polymer synthesis and processing, and rheological studies is desirable.

• Technical Skills Required to Perform This Job

• Personal computer skills and applicable software.
• Good interpersonal and communication skills.
• Good business writing ability.
• Strong background in Polymer Chemistry and Catalysis.
• In-depth knowledge of polymer structure-property relationship.
• Background in polymer processing and additives formulation.
• In-depth knowledge of analytical chemistry and polymer characterizations.
• Familiar with the manufacturing parameters and polymer structure/property

relationships.

• Knowledge in polymer fabrication processes and manufacturing operations.
• Ability to collect, analyze, and interpret data from commercial plant operations.
• Strong analytical and problem solving skills.

• Education

A B.S. degree in an engineering discipline, such as Mechanical, Process, or Chemical Engineering, is required. An M.S. degree in Polymer Science, Materials Science, Chemical Engineering, Chemistry, or a closely related field is preferred. A Ph.D. in one of these disciplines is a plus. Candidates with degrees in other engineering disciplines from ABET-accredited universities may also be considered.

• Other Certification/Training Required

• Will require training in Company Policies and Procedures after hire.
• Current employees must meet all technical and safety training requirements for

current position, as specified in the Master Training Plan.

Check Out Our Benefits

Health Coverage and Perks

Excellent medical, dental, and vision insurance plans

Flexible spending accounts for health, dependent care

Short-term Disability

Long-term Disability

Group Term Life, Dependent and

Supplemental Life Insurance

Tuition Reimbursement

​​​​​​​

Work/Life Balance

10 Paid Holidays

Paid Time Off for a balanced life

(Vacation, Sick and Personal Time)

FlexTime Available

Competitive Compensation

Competitive salary, incentive/bonus, 401(k) plan with company match,

Cash Balance, Pension Plan