REPORTS TO: Plant Manager
DIRECT REPORTS: Process Technician(s) and Preventative Maintenance and Tooling/Set-up employees
FLSA STATUS: Exempt
ROLE:
The Process Engineer is responsible for leading plant activities to ensure that equipment, tooling, and processes are maintained in proper operating condition to ensure that finished products are made to specifications at optimal process rates. Responsibilities are to be completed with consideration of safety, cost, efficiency, timeliness and production of a quality product within specifications and minimal defects. This is a highly collaborative position requiring strong organizational, follow up and communication skills. The ability to cultivate relationships with corporate and manufacturing teams, vendors and customers is essential in the achievement of objectives.
ESSENTIAL DUTIES AND RESPONSIBILITIES:
- Become the process expert in the areas of sheet extrusion and plug-assisted thermoforming
- Ensure process and product stability.
- Establish well documented and in control production processes.
- Ensure that accurate and up-to-date process condition sheets are posted and being followed on each production line
- Ensure established process conditions produce product that meet specifications.
- Be available in person or via phone after hours and on weekends to assist in resolving plant issues as needed.
- Train personnel on new equipment operations and safety requirements.
- Provide on-the-job and/or classroom training for line operator and troubleshooting sessions as needed.
- Develop training materials and ensure they are updated as needed
- Develop equipment and process training manuals for operators.
- Lead and/or assist in the development, training and compliance of safe operation procedures
- Support cross-training for maintenance, automation, tooling and process employees.
- Direct responsibility for the management of the plant Process Technicians and Tooling and Set-Up Teams
- Create a positive work environment by ensuring an “Open Door” culture and fostering the positive exchange of ideas.
- Develop employees for next level opportunities to ensure your and their progression within the organization.
- Participate in the performance management process through positive reinforcement, goal-setting and disciplinary action in conjunction with human resources and plant management.
- Track employees work time including the maintenance of timecards, attendance records, paid and unpaid time off request management and coordination for adequate shift coverage.
- Lead the Preventative Maintenance and Tooling/ Set-up Teams
- Develop maintenance and cleaning protocols for extrusion / thermoforming tooling.
- Continuously reduce line changeover time and improve post changeover line productivity
- Work with plant maintenance team to troubleshoot equipment operating issues and develop corrective and preventive actions to avoid them
- Assist in optimizing plant maintenance programs for new equipment
- Lead plant and assist corporate engineering and quality in the development of processes for new and existing equipment and products
- Communicate and coordinate product start-ups and corporate/R&D trials in production facilities.
- Participate in the completion of safety New & Altered Equipment Reviews (NAERs) and
- Ensure proper quality gauge & testing set-up
- Ensure products meet specifications.
- Lead plant and assist in corporate continuous improvement efforts to improve process and equipment productivity.
- Assist in optimizing plant maintenance programs for new equipment.
- Lead plant and assist in corporate cost reduction programs as assigned.
- Continuously reduce line changeover time and improve post changeover line productivity
- Demonstrate ability to initiate and perform root cause analysis and implement corrective action to drive improvement.
- Assist in preparation of and manage plant capital and expense budgets.
TECHNICAL COMPETENCIES:
Interpersonal/Communication:
- Ability to participate and/or foster interdepartmental communication and teamwork.
- Ability to prioritize multi-task duties without loss of efficiency or composure.
- Effective written and verbal communication and presentation skills to conduct effective meetings and disseminate information in a timely and diplomatic manner
- Ability to work under pressure, meet scheduled deadlines, respond to emergency situations without loss of efficiency or composure.
- Communicate regularly and pro-actively with all levels of employee regarding problems or issues impacting processes.
- Ability to establish and build relationships with internal/external customers.
- Strong record keeping, management of change, and training skills will be key in successfully implementing consistent processes.
- Effective leadership skills and the ability to motivate, train, and delegate responsibility to direct and indirect reports.
- Demonstrated ability to work without supervision.
- Demonstrates the servant leadership values of valuing people, humility, listening, trust and caring toward the employees under their stewardship.
- Demonstrates a high level of responsiveness to employee concerns and ideas for improvement.
Technical Knowledge:
- Process expert in the areas of sheet extrusion, different materials, forming and trimming of thermoformed products and automation.
- Stay up to date on evolving equipment and methods, implementing as necessary.
- Good understanding of mechanical and electrical principles and applications.
- Ability to read and interpret mechanical equipment and tooling prints.
- Assist in keeping the plant in compliance with all Local, State and Federal regulations
- Exemplify and ensure compliance with the requirement of GMP, SPC, SQF, Safety and Standards of Conduct policies and procedures.
Safety:
- Demonstrated ability to comply with all Company policies and procedures and to uphold, support and exemplify the safety programs and standards.
- Ensure group and plant meet Genpak safety goals while maintaining OSHA compliance.
EDUCATION & EXPERIENCE:
- BS in Engineering Technology/Engineering with 3 years of plastic processing experience
OR
- Equivalent work experience and 5 years in plastics processing experience
- Previous experience managing one or more hourly or salary reports.
- Previous project management experience required
- Experience working in multiple facilities
- Demonstrated analytical thinking and problem-solving skills
- Strong interpersonal skills to be able to train, communicate, and lead effectively.
- Knowledge of MS Office and familiarity with database applications.
- Knowledge of polymer physical properties and behaviors
- Experience with plastics thermoforming processing machinery
- Demonstrated analytical thinking and problem-solving skills.
- Speaking and presentation skills to conduct effective meetings.
ADA – ESSENTIAL FUNCTIONS:
Must be able to:
- Work an 8-hour shift with overtime as required.
- Sit, stand and/or walk frequently
- Speak and hear constantly
- Use of fingers, hands and arms constantly
, Montgomery, Alabama 36064
3255 Thomason Avenue, Montgomery, Alabama 36108
, Prattville, Alabama 36066
, Autaugaville, Alabama 36003
, Millbrook, Alabama 36022
