Process Engineer

Position Summary

The Rollstock Extrusion Process Engineer is responsible for owning, optimizing, and advancing polymer film extrusion processes that produce Rollstock for packaging applications. This position operates with a high degree of independence and serves as a key technical resource for Manufacturing, Quality, Maintenance, and Product Development. The role focuses on improving process capability, reliability, yield, and safety while leading complex projects that support business growth and operational excellence.

Job Description

Process Ownership & Technical Leadership
Serve as the technical owner for Rollstock extrusion processes, ensuring stable, capable, and repeatable operation across shifts and product mixes.
Independently diagnose and resolve complex extrusion issues related to materials, rheology, temperature control, die systems, bubble or web stability, thickness profile, and downstream handling.
Establish and maintain robust process control strategies, including centerlines, control plans, SPC, in-line vision system, gauge control systems, and standard work.
Reduce process variation, scrap, and unplanned downtime through data-driven root cause analysis and sustained corrective actions.

Continuous Improvement & Operational Excellence
Lead continuous improvement initiatives using Lean and Six Sigma tools to improve yield, rates, setup time, and overall equipment effectiveness.
Apply statistical methods and designed experiments (DOE) to optimize process windows and performance.
Support daily management systems and coach operators and technicians in structured problem-solving.

Capital Projects & Technology Deployment
Lead or serve as lead engineer on extrusion-related capital projects, including equipment upgrades, new line installations, and major modifications.
Participate in equipment specification, vendor selection, factory acceptance testing (FAT), site acceptance testing (SAT), commissioning, and startup.
Evaluate new extrusion technologies and automation solutions and translate successful trials into production standards.
Utilize and expand MES capabilities for improved process control, material tracking, and schedule adherence

Product & Process Development
Partner with Product Development and Quality to support resin qualifications, product transitions, and raw material changes.
Lead technical execution for process scale-ups, trials, and commercial launches.
Identify and execute long-term technical solutions that eliminate recurring issues.

Quality, Safety, and Compliance
Support and strengthen quality systems through effective use of SPC, FMEA, and corrective/preventive action methodologies.
Lead or support complex failure investigations and ensure permanent corrective actions are implemented and verified.
Ensure all process changes comply with safety, environmental, and regulatory requirements.
Proactively identify and mitigate process safety and EH&S risks associated with extrusion operations.

Documentation & Knowledge Sharing
Prepare clear technical documentation including trial reports, process standards, equipment specifications, and lessons learned.
Effectively communicate technical findings and recommendations to operations leadership and cross-functional teams.
Act as a technical mentor for less experienced engineers and technical staff.

Qualifications

Education & Experience
Bachelor’s degree in Chemical, Mechanical, Polymer, Plastics Engineering, or related field.
Minimum 3–5 years of extrusion or polymer manufacturing experience, preferably in blown, cast, and/or oriented film, with a proven ability to work independently on complex technical challenges.

Technical & Operational Skills
Strong understanding of polymer processing, extrusion equipment, materials behavior, and film properties.
Demonstrated proficiency in statistical analysis, SPC, root cause analysis, DOE, and project execution.
Hands-on experience applying Lean and Six Sigma tools; Green Belt or Black Belt preferred.
Ability to manage multiple projects while meeting cost, quality, and delivery objectives.
Leadership & Communication
Effective written and verbal communicator with experience leading cross-functional teams and influencing without direct authority.

Preferred Qualifications
Experience with multilayer film structures, resin systems (PE, PA, EVOH, tie layers), and gauge/profile control.
Exposure to extrusion capital projects, automation, advanced process controls, and product commercialization.
Experience developing proprietary processes, technical standards, or intellectual property.

Working Conditions
Manufacturing environment with regular shop-floor engagement.
Occasional off-shift or weekend on site or remote support for trials, start-ups, and troubleshooting.
Travel up to 10% for suppliers, vendors, or other manufacturing sites.