Associate R&D Process Engineer

carlislecompanies; Greenville (IL); On-site; USD 90,000 - 115,000; Full time

Job summary

Carlisle Construction Materials is seeking an R&D Process Engineer - Plant Focused to drive process improvements across our production facilities. You will analyze data on defects, downtime, and efficiency, lead trials, and implement new processes and equipment with Lean and DOE methodologies.

Working closely with plant leadership, you will develop technical roadmaps, mentor personnel, and maintain SAP-driven process controls to ensure cost effective, high-quality manufacturing.

Qualifications

• Bachelor's degree in Engineering or related technical discipline.
• 3+ years of plastic or rubber processing experience in a technical role; 5+ years preferred.
• Experience with SPC, DOE, and statistical analysis.
• Lean Six Sigma certification preferred.

Responsibilities

• Identify and implement process improvements that reduce defects, scrap, rework, downtime, and operating costs.
• Provide hands-on technical support and troubleshooting to plant production teams.
• Develop and maintain process specifications, controls, and statistical process control systems.
• Lead manufacturing projects, R&D trials, new product launches, and capital improvement initiatives.
• Support Carlisle Operating System (COS) and Lean initiatives, including tiered accountability and layered audits.
• Develop technical roadmaps and provide mentorship to plant personnel and managers.
• Maintain process information systems, including SAP, process control, dimensional control, and production reporting systems.

Skills

Process engineering

Lean Six Sigma

Project management

Education

Bachelor's degree in Engineering/related

Tools

SAP

Job description

R&D Process Engineer - Plant Focused

Carlisle Construction Materials (CCM) is seeking an R&D Process Engineer - Plant Focused to drive process improvements, technical problem solving, and manufacturing innovation within our production facilities. This role works closely with plant leadership and production teams to improve quality, productivity, reliability, and cost while supporting the development and implementation of new processes, technologies, products, and equipment.

As a key technical resource within the plant, you will analyze process data—including defects, scrap, rework, downtime, and OEE—to identify opportunities and implement sustainable improvements. You'll work hands-on with production personnel to troubleshoot materials, methods, and equipment while developing expertise across compounding, extrusion, web handling, adhesive coating, and related manufacturing processes.

You'll also lead and support projects involving new technology, cost reduction, R&D trials, new product and process start-ups, and capital equipment improvements. Using Lean methodologies, statistical process control, DOE, DMAIC, A3, and other structured problem-solving tools, you'll help establish robust processes and build a culture of continuous improvement.

Key Responsibilities:

• Identify and implement process improvements that reduce defects, scrap, rework, downtime, and operating costs
• Provide hands-on technical support and troubleshooting to plant production teams
• Develop and maintain process specifications, controls, and statistical process control systems
• Lead manufacturing projects, R&D trials, new product launches, and capital improvement initiatives
• Support Carlisle Operating System (COS) and Lean initiatives, including tiered accountability and layered audits
• Develop technical roadmaps and provide mentorship and guidance to plant personnel and managers
• Maintain process information systems, including SAP, process control, dimensional control, and production reporting systems

Qualifications:

• Bachelor's degree in Engineering, Science, or a related technical discipline
• 3+ years of plastic or rubber processing experience in a technical support role; 5+ years preferred
• Knowledge of plastics manufacturing, compounding, extrusion, sheeting, and web-handling processesExperience with SPC, DOE, statistical analysis, and structured problem-solving methodologies
• Strong project management, communication, and interpersonal skills
• Lean Six Sigma certification and plastics technology coursework preferred

This position typically works Monday-Friday, with approximately 10-25% travel based on business needs.