Process Engineer- Carpet Coating

Role Summary

Owns and supports all modular carpet coating-related manufacturing processes, with primary responsibility for TL2, VAE, Shearing, Vinyl Compounding, and BL Compounding. This role drives process capability, product quality, cost, safety, and uptime by applying disciplined troubleshooting, process control, standardization, and continuous improvement across coating and compounding operations.

Key Responsibilities

• Provide day-to-day technical ownership for TL2, VAE, Shearing, Vinyl Compounding, and BL Compounding processes, including start-ups, changeovers, and troubleshooting.


• Establish and maintain process standards (recipes, setpoints, run conditions, work instructions) to ensure consistent coating weight, adhesion, cure, surface finish, and dimensional stability.


• Lead root-cause problem solving for defects and downtime (e.g., coat-weight variation, pinholes, streaks, poor adhesion, gel/contamination, viscosity drift, shear marks, delamination, appearance issues); implement corrective and preventive actions.


• Optimize formulations and compounding parameters for vinyl and backing compounds (mixing sequence, temperature control, dispersion, filler loading, plasticizer/additive control) to meet performance, cost, and processing targets.


• Partner with Quality to define critical-to-quality characteristics and control plans; use SPC and capability studies to reduce variation and improve first-pass yield.


• Plan and execute trials for new products, materials, equipment, and process changes; define sampling plans, evaluate results, and standardize successful conditions.


• Collaborate with Maintenance and Engineering to improve equipment reliability (mixers, extruders, pumps, coaters, ovens, shears); define settings, PM improvements, and critical spares.


• Drive waste, scrap, and rework reduction through loss analysis, line audits, and targeted kaizen/lean projects; quantify savings and sustain gains.


• Maintain accurate technical documentation including process sheets, SOPs, troubleshooting guides, training materials, and change-control records.


• Train and coach operators and technicians on process fundamentals, standard work, safe operation, and response plans for out-of-spec conditions.


• Support safety and environmental compliance within compounding and coating operations, including chemical handling, housekeeping, and risk assessments.


• Analyze performance metrics (OEE, uptime, scrap, consumption, coat weight, viscosity, throughput) and communicate daily/weekly action plans to stakeholders.

Primary Objectives

• Improve profitability by reducing compound and coating material consumption and overall conversion cost.


• Increase process capability and stability (reduced variation) across TL2, VAE, Shearing, and compounding operations.


• Improve quality and delivery by minimizing scrap/defects and increasing OEE through faster troubleshooting and sustained standard work.

Qualifications

• Working knowledge of polymer processing and web/coating manufacturing (compounding, extrusion, coating application, drying/curing, and converting/shearing).


• Strong process control and problem-solving skills (5-Why, fishbone, DOE, capability/SPC); able to translate data into actionable changes on the floor.


• Effective cross-functional communicator who can lead initiatives with Operations, Quality, Maintenance, EHS, and Supply Chain in a fast-paced manufacturing environment.


• Experience supporting continuous improvement in manufacturing (lean tools, loss analysis, standard work, and sustainment).


• Proficiency with basic data tools (Excel or equivalent) and manufacturing systems for tracking scrap, downtime, and process parameters.


• Ability to provide hands-on support on the production floor, including off-shift troubleshooting as needed.

Education

• Bachelor’s degree in Mechanical, Manufacturing, Chemical, or Materials Engineering (or equivalent experience).


• Additional coursework or experience in polymer/rubber science is a plus.

Key Interfaces

• Operations/Shift Leaders and Line Operators (daily support, standard work, issue resolution)


• Quality (control plans, defect reduction, customer/internal nonconformances)


• Maintenance/Engineering (equipment performance, reliability, improvements)


• EHS (safe chemical handling, risk assessments, compliance)


• Supply Chain/Procurement and Suppliers (raw material changes, trials, specifications)

Safety, Quality & Compliance

• Follow and reinforce all plant safety rules, including LOTO, chemical handling, PPE, and safe work practices around rotating equipment, high temperatures, and moving webs.


• Participate in incident investigations and risk assessments; implement corrective actions to prevent recurrence.


• Support product and process compliance requirements by maintaining specifications, change control, and required documentation.


• Promote quality culture by ensuring controls are in place, understood, and sustained across shifts.

Work Enviroment & Physical Requirements

• Manufacturing environment with exposure to noise, airborne particulates, heat, and chemicals typical of compounding and coating operations.


• Frequent time on the production floor observing processes, collecting samples, and supporting troubleshooting.


• May require standing/walking for extended periods and occasional lifting of materials/samples as permitted by site policy.