Foam Process Engineer

Morgan Truck Body; Morgantown (PA); On-site; USD 80,000 - 105,000; Full time

Benefits offered by this job

Medical benefits

Dental coverage

Vision coverage

401(k) with match

Tuition reimbursement

Job summary

Morgan Truck Body in Morgantown, PA is seeking a Foam Process Engineer to optimize polyurethane foam production, troubleshoot equipment, and drive quality, safety, and productivity. You will work cross-functionally with Manufacturing, Quality, and Engineering to solve problems and improve performance.

The role requires 5+ years of polyurethane foam experience, knowledge of resin/isocyanate systems, and hands-on process optimization. Travel ~50% across North America will be needed.

Qualifications

• Bachelor’s degree in a related technical field preferred or equivalent experience.
• 5+ years of polyurethane foam systems experience.
• Experience with meter-mix-dispense systems and PLC-controlled equipment.
• Strong data analysis and root-cause problem-solving abilities.
• Manufacturing or transportation industry experience preferred.
• Willingness to travel up to 50% across US/Canada.

Responsibilities

• Monitor and optimize polyurethane foam dispensing and mixing processes.
• Audit foam processing equipment and establish maintenance standards.
• Ensure foam meets density, adhesion, and performance requirements.
• Investigate defects and implement corrective actions (CAPA).
• Improve formulations and process parameters to increase yield and reduce scrap.
• Analyze production trends and support process validation activities.

Skills

Foam process

Polyurethane chemistry

Data analysis

Root cause analysis

Manufacturing experience

PLC & control systems

MS Office / data systems

Education

Bachelor’s degree in Chemical, Mechanical, Manufacturing, Materials Engineering, or related technical field

Tools

Meter-mix-dispense systems

PLC-controlled equipment

Process monitoring

Job description

Foam Process Engineer

From Chemistry to Quality-Engineer What’s Possible!

Location: Morgantown, PA

Your Impact – Big and Bold!

Put your process expertise to work where it makes an impact. As a Foam Process Engineer, you’ll optimize polyurethane foam production processes, troubleshoot equipment and material challenges, and use data to drive improvements in quality, consistency, safety, and productivity. Working hands‑on with resin and isocyanate systems, you’ll partner across Manufacturing, Quality, and Engineering to solve problems and continuously improve performance.

What a Day in Your Life Looks Like:

• Process Control: Monitor and optimize polyurethane foam dispensing and mixing processes, including resin/isocyanate ratios, temperatures, pressures, flow rates, and shot weights.

• Equipment Performance: Audit foam processing equipment, troubleshoot issues with Maintenance, and establish preventive maintenance and calibration standards.

• Quality Assurance: Ensure foam meets established density, adhesion, dimensional stability, fill, and performance requirements.

• Root Cause & CAPA: Investigate foam defects-including voids, shrinkage, adhesion, density, fill, and delamination issues-and implement effective corrective and preventive actions.

• Process Optimization: Improve formulations, application methods, and process parameters to increase yield, material utilization, cycle time, scrap performance, and process capability.

• Data & Validation: Analyze production and quality trends, conduct capability studies, and support process validation activities.

• Materials & Suppliers: Partner with suppliers to evaluate raw material performance, resolve resin and isocyanate issues, and qualify new chemicals, suppliers, and equipment.

• New Product Support: Provide foam process expertise for new product development, trials, and manufacturing implementation.

• Documentation & Compliance: Maintain SOPs, work instructions, control plans, specifications, and quality records while ensuring compliance with chemical-handling and EHS requirements.

• Technical Leadership: Serve as the polyurethane foam subject matter expert, providing hands‑on troubleshooting, training, and technical support to Production, Maintenance, and Engineering teams.

What You Bring to the Table:

• Education & Experience: Bachelor’s degree in Chemical, Mechanical, Manufacturing, Materials Engineering, or a related technical field preferred; equivalent education and relevant experience considered.

• Foam Process Expertise: 5+ years of experience with polyurethane foam systems, chemical processing, or automated dispensing equipment preferred.

• Polyurethane Knowledge: Understanding of polyurethane chemistry, resin/isocyanate systems, and foam manufacturing processes.

• Equipment & Controls: Experience with meter-mix-dispense systems, PLC-controlled equipment, and process monitoring, including troubleshooting mixing and dispensing systems.

• Data & Problem Solving: Ability to analyze process data, apply statistical methods, and use root cause analysis to solve manufacturing challenges.

• Manufacturing Experience: Experience in transportation, automotive, construction products, refrigeration, or a similar manufacturing environment preferred.

• Systems & Technology: Proficiency with Microsoft Office and manufacturing data systems.

• Travel: Ability to travel approximately 50% across manufacturing locations in the U.S. and Canada.

Physical Requirements:

• Work in an active manufacturing plant environment where hands‑on tasks keep you engaged! This role requires working in a non-climate-controlled setting, with regular talking and listening. You’ll frequently stand, walk, and use your hands to handle, feel, and reach as you complete your daily duties with precision. Occasionally lifting up to 25 lbs.

Why Morgan? Because You Deserve the Best:

With over 70 years leading the truck body industry, Morgan Truck Body is where innovation meets tradition. From electric vehicles to custom refrigerated units, we build it all - and we do it with passion and precision.

See our story:

A History of Morgan

We offer:

• Competitive pay and full benefits package (medical, dental, vision, life)- your health matters

• 401(k) with company match - because your future matters

• Tuition reimbursement and leadership development to boost your career

• Paid holidays and vacation time - we know balance is key

• Exclusive discounts on footwear, eyewear, and safety gear- because we care about your safety

Join a team where your impact is real, your growth is limitless, and your work fuels the future of transportation!

What Drives Us at Morgan:

At Morgan Truck Body, our shared values aren’t just words on a wall - they’re the heart of everything we do. They fuel our success, shape our culture, and guide how we show up for each other, our customers, and the future of transportation.

We Celebrate People

We recognize and value the individuals behind the build - the makers, thinkers, and problem-solvers who drive our success every day.

We Lead with Integrity

Doing the right thing isn’t optional - it’s how we operate, always. Honesty, accountability, and respect guide every decision.

We Deliver Results

We show up, step up, and get it done. Our commitment to performance means exceeding expectations and raising the bar - for ourselves and our customers.

We Work with Passion

We love what we build - and it shows. From the factory floor to the front office, we bring energy, innovation, and pride to every product that rolls out of our doors.

At Morgan Truck Body, part of the J.B. Poindexter & Co. family, we’re committed to building a workplace where everyone feels respected, supported, and empowered to succeed.

We are proud to be an equal opportunity employer. We welcome and celebrate diverse perspectives and do not tolerate discrimination or harassment of any kind - regardless of race, color, religion, age, gender, national origin, disability status, genetics, veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by law.

This commitment applies to every part of your journey with us - from hiring and promotions to compensation, training, and beyond.

Diversity drives innovation. Inclusion fuels our strength.

At Morgan, everyone belongs.

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