Process Engineer I

Role details

Toray Advanced Composites (TAC) is a leading supplier of advanced composite materials for the aerospace, sporting goods, motorsport, and industrial markets. You will find our thermoset composite products on nearly every satellite, space launch vehicle, unmanned aircraft, military and commercial aircraft in production today. TAC also provides composites materials to industrial and recreational applications including mountain bikes, medical prosthetics, and sports equipment.

Our thermoplastic prepregs, known in the industry as Cetex®, are found in a wide range of commercial and military aircraft, including large wing structures and interior applications like seats and galleys. Our Cetex products are available in unidirectional tape or fabric form in a variety of engineered thermoplastic resins including PEEK, PPS, PEI as well as a full line of performance thermoplastics including Nylon, PET, HDPE, and PP.

SUMMARY OF FUNCTIONS

The Process Engineer I will work under guidance/mentorship of a senior level process engineer by taking technical ownership of the production process/product lines. The engineer will learn and understand for complete process control and learn and provide technical oversight of a continuous production process, to ensure maximum up-time, with highest efficiency and excellent quality. Additionally, the engineer will support production by shadowing the senior engineer, new product development and production integration. This is a hands-on process engineering role, and will require ingenuity, flexibility and problem-solving capabilities.

A primary objective is to maintain and recommend improvements to the consistency of the production processes, recommend updates to process control, and support production/equipment upgrades. The process engineer will fully comprehend the methodology and techniques to produce continuous reinforced composite materials.

Please note roles and responsibilities are subject to change with or without advanced notice.

MAJOR DUTIES AND REQUIREMENTS

Under guidance of a more senior level process engineer or designee:

• Learn and understand all process engineering activities across a broad range of processes, ranging from manufacturing, process control/optimization, scrap reduction, and to support engineering trials.

• Ability to recognize and troubleshoot problems associated with impregnation or batch mixing manufacturing processes.

• Support in establishing and measuring process performance standards associated with quality, waste/throughput.

• Provides feedback to operational reviews and other efforts leading to safety/quality/process improvements and cost reduction activities.

• Assist when needed in investigations and resolve operational non-conformances and customer related issues.

• Under direction, plan and execute capital programs and process improvement activities.

• Assist when needed in customer site audits/qualifications and visits at Toray.

• Provide support in targeted projects which include defining and documenting product and processing parameters, capability, cost reductions and manufacturing.

• Have the ability to evaluate, troubleshoot, and solve process problems on the production floor.

• Documenting manufacturing processes and methods per AS9100 (or equivalent) quality system.

• Create and maintain part numbers, manufacturing Configurations, Bills of Materials, Routes, Work Instructions, SPC/SQC, and Control Plans using manufacturing engineering best practices.

• Works with all related functions including Manufacturing, Maintenance, Process Technology, R&D, Quality Assurance and Receiving/Shipping to achieve the company's objectives.

• Must be able to support multiple projects.

• Assists in responsibility for the safety and environmental issues associated with the manufacturing processes and equipment.

• Supports process engineering and operation department leads/managers in his/her functional activities, and performs other duties as assigned.

• Must be available and willing to work during off hours when needed.

EXPERIENCE AND/OR EDUCATION REQUIREMENTS

• Bachelor’s degree in material science, engineering, chemical, mechanical or related degree

• Less than three years of experience working in composite materials, aerospace manufacturing industry

• Internship experience is preferred

• Lean and Six Sigma training is a plus

• Familiarity with RCCA, PFMEA, Statistics & SQC/SPC is preferred

• Knowledge of business ERP system is a preferred (Microsoft D365 or similar)

• Must be able to communicate clearly (written and verbally) in English

• Able to work and communicate effectively with multiple teams

• Maintain work areas in a neat, orderly and safe manner

• Follow safety procedures for PPE (personal protection equipment)

Salary range:  $90,000 - $115,000 annual

Toray Advanced Composites employment practices offer equal employment opportunity and does not discriminate against its employees or applicants because of race, color, religion, sex, pregnancy, national origin, ancestry, age, marital status, physical or mental disability, medical condition, sexual orientation, or any other basis prohibited by law. Equal employment opportunity will be extended to all persons in all aspects of the employer/employee relationship, including recruitment, hiring, training, promotion, transfer, discipline, layoff, recall, and termination