Lead, Manufacturing Engineer Process Extrusion, Air Manufacturing Innovation

Nike; Saint Charles (MO); On-site; USD 110,000 - 170,000; Full time

Job summary

Nike Air MI is seeking a Lead, Process Engineer to develop, optimize, and sustain extrusion manufacturing processes for Nike Air components. You will drive process capability, readiness, and standardization in a Lean environment, collaborating across Quality, Automation, and Production to deliver scalable, data-driven solutions.

You will apply Six Sigma, lean principles, and digital-twin style analyses to reduce scrap, improve OEE, and elevate process excellence across the Air MI network within

Qualifications

• At least 6 years in process engineering in high-volume manufacturing.
• Bachelors degree in plastics, chemical, mechanical, manufacturing or industrial engineering (or suitable mix).
• Experience with Six Sigma, lean manufacturing and statistical analysis.

Responsibilities

• Lead and optimize extrusion processes to improve OEE, CpK, and throughput.
• Drive continuous improvement using data-driven methods and digital tools.
• Lead root cause investigations and complex troubleshooting of process failures.
• Develop and validate control plans, process specs, and standard work.
• Collaborate with Quality Systems, Automation, and Production teams to standardize Air MI manufacturing.

Skills

Six Sigma

Lean Manufacturing

Statistical Modeling

Process Simulation

Digital Twin

Root Cause Analysis

Education

Bachelors in Plastics/Chemical/Mechanical/Manufacturing/Industrial Engineering

Tools

Process Simulation Software

Job description

WHO YOU'LL WORK WITH

The Lead, Process Engineer at Air MI is an extrusion technical leader within Air Manufacturing Engineering responsible for developing, optimizing, and sustaining the manufacturing processes used to create Nike Air components. This role drives process capability and manufacturing readiness in alignment with the ambitions of the Air MI Manufacturing System (AMS) - focusing on standardization, flow, stability, and Lean-driven continuous improvement.

This role will report to the Sr Manager, Process Engineering in AM93 in St. Charles and will partner closely with Product Development Materials Innovation, Quality Systems Engineering, Automation Engineering, and Air Manufacturing Operations to deliver safe, scalable, standardized, data-driven processes that enable Air MI to meet demand, reduce scrap and waste, and operate as a standardized global network.

WHO WE ARE LOOKING FOR

The Lead, Process Engineering , is a key member of the Manufacturing Engineering team that delivers AIR and is expected to: mentor process engineers engineering and manufacturing best practices; drive process optimization, technical excellence and deliver quality; integrate digital and automation solutions; lead continuous improvement and team collaboration with emphasis on Lean Six Sigma; and promote workplace safety. This role will elevate, evolve, and drive manufacturing process engineering best practices and standards while driving the adoption of real-time data systems. The right person for this role will bring experience in critical-to-quality control plans, statistical process control, PFMEA, process validations, predictive modeling or digital twins and excel in process simulation. You need to be solutions oriented, decisive and bring a hands‑on approach to teaching and problem solving with a proven track record of improving efficiencies in processes as well as driving accountability.

Required:

• Experience - At least 6 years in process engineering within a high-volume manufacturing production environment in Plastics, Semiconductor, Technology or Food & Beverage industries.
• Education – bachelor’s degree in plastics, chemical, mechanical, manufacturing or industrial engineering, will accept any suitable combination of education, experience or training
• Technical – process simulation/optimization/digital twin technology, Six Sigma, lean manufacturing, Statistical modeling/analysis
• Experience troubleshooting complex manufacturing equipment utilizing mechanical, process, and automation fundamentals.

Preferred:

• Experience in Thermoplastic Polyurethanes materials, sheet extrusion and extrusion processing equipment.
• Experience in product development and validation in a high-volume manufacturing environment.
• Lean Six Sigma Green Belt or Black Belt certification.
• Proven ability to work with associates of all levels including machine operators, supervisors, experts, engineers, technicians, and executives, while adapting communication style to suit different audiences.

WHAT YOU'LL WORK ON

The Lead, Process Engineer, at Air MI will be responsible for developing, optimizing, and sustaining the manufacturing processes used to create Nike Air components. This role drives process capability and manufacturing readiness in alignment with the ambitions of the Air MI Manufacturing System (AMS) - focusing on standardization, flow, stability, and Lean-driven continuous improvement.

You will partner closely with Quality Systems engineers, Automation Engineers, and Air/Sheet Production to deliver safe, scalable, data-driven processes that enable Air MI to meet demand, reduce scrap, modernize equipment strategies, and operate as a unified global network. You get to:

• Serve as technical SME for AM93 manufacturing processes, providing expert guidance on extrusion, material processing, tooling interactions, and process capability improvement.
• Lead complex troubleshooting and root cause investigations involving quality losses, downtime, process variation, yield reduction, scrap generation, and equipment reliability issues.
• Lead process design, validation, capability and optimization, ensuring stable, robust processes that meet throughput, OEE, and Cpk requirements while supporting Air MI network standardization
• Ownership mindset to drive process optimization and continuous improvement initiatives utilizing engineering fundamentals, statistical analysis, experimental design, RCAs, and advancing data-driven digital and automation solutions to improve OEE, quality rate, performance rate, throughput, and cost performance.
• Oversee process monitoring and troubleshooting, enabling rapid response to abnormalities and improving machine availability through expert understanding of materials, tooling, equipment, and key machine operating parameters
• Ensure documentation creation and validation rigor, including control plans, process specs, validation packages, and standard work in partnership with Air Standards and Quality Systems
• Leverage manufacturing data systems and digital tools to identify trends, predict process performance, improve decision-making, and advance data-driven manufacturing practices.
• Establish and maintain process standards, including process specifications, control plans, standard work, validation protocols, engineering documentation, and best practices.

We offer a number of accommodations to complete our interview process including screen readers, sign language interpreters, accessible and single location for in-person interviews, closed captioning, and other reasonable modifications as needed. If you discover, as you navigate our application process, that you need assistance or an accommodation due to a disability, please complete the Candidate Accommodation Request Form.