Manufacturing Process Engineer

Novolex; Connersville (IN); On-site; USD 75,000 - 110,000; Full time

Job summary

Novolex is seeking a Process Engineer to troubleshoot and optimize manufacturing processes, drive continuous improvement, and improve product quality across our production sites. The role emphasizes data analysis, process capability studies, and leading Kaizens to reduce variation and increase uptime.

The candidate will work on process control initiatives, collaborate with maintenance, and develop training programs to elevate workforce expertise.

Qualifications

• B.S. degree in Engineering – preferably with concentration in plastics/material science, or, in the absence of a plastics degree a minimum of 5 years engineering experience in extrusion, thermoforming processes or plastics processes.
• Strong skillset in sheet extrusion and inline thermoforming.
• Working knowledge of statistical process control, design of experiments and quality systems.
• Background in continuous improvement process and principles – 5-10 years of prior experience participating in and preferably leading focused improvement teams is a must.
• Superior supervisory experience – directing work, coaching, managing performance and development; ability to coach and train at all levels.

Responsibilities

• Troubleshoot problems associated with manufacturing processes.
• Conduct tests and monitor the process performance throughout production.
• Identify and reduce process variation within tolerable limits using data and process controls.
• Utilize current and historical data to identify opportunities for improved efficiency and control.
• Champion process control efficiency and continuous improvement initiatives.
• Mine and analyze production data to identify trends, risks, and opportunities.
• Drive understanding of process control methodology to minimize reactive quality checks.
• Perform process capability studies, DOE, and statistical process control analysis.
• Lead and support structured problem-solving activities (Kaizens, A3s, etc.).
• Identify high-performing assets and replicate best practices across operations.
• Evaluate and implement process improvements for production operations.
• Train and educate employees on process integrity, control, and best practices.
• Develop and maintain technical training programs and trouble shooting guidelines.
• Support onboarding and ongoing training for new and existing employees.
• Support equipment upgrades, retrofits, and reliability initiatives.
• Partner with Maintenance and operations to improve equipment uptime and performance.
• Manage process-related risks and highlight potential issues proactively.
• Determine technical and economic feasibility of process improvements and new programs.
• Develop capital estimates for new products or equipment investments.

Skills

Supervisory experience

Sheet extrusion

Inline thermoforming

Statistical process control

Design of experiments

Quality systems

Continuous improvement

Coaching & training

Education

B.S. degree in Engineering with plastics/material science

Job description

Novolex is a leading manufacturer of food, beverage, and specialty packaging that supports multiple industries including foodservice, restaurant delivery and carryout, food processing, grocery and retail, and industrial sectors. Novolex manufacturing and sourcing expertise spans a diverse range of substrates including resin, paper, molded fiber, aluminum and more. We provide customers a broad array of stock and customized solutions with 120 product categories, 250 brands and over 39,000 SKUs.

Our Sustainability Commitment

The Novolex sustainability vision is built upon three pillars: our products, our operations and our people. Each is critically important to our growth and future as a business. These pillars form the foundation of our company-wide commitment to sustainability, helping us achieve our ambitious goals through our wide-ranging initiatives.

The Process Engineer is responsible for troubleshooting and optimizing manufacturing processes, while driving improvements in operational efficiency, waste reduction, process uptime, and equipment reliability. This role serves as a technical resource for all processing equipment, leads process control initiatives, and supports training and continuous improvement efforts across the site.

The Process Engineer will leverage data, process knowledge, and continuous improvement methodologies to reduce process variation, improve product quality, and enhance overall plant performance.

Essential Functions & Key Responsibilities:

Process Optimization and Troubleshooting

• Troubleshoot problems associated with manufacturing processes.
• Conduct tests and monitor the process performance throughout production.
• Identify and reduce process variation within tolerable limits using data and process controls.
• Utilize current and historical data to identify opportunities for improved efficiency and control.

Process Control and Data Utilization:

• Champion process control efficiency and continuous improvement initiatives.
• Mine and analyze production data to identify trends, risks, and opportunities.
• Drive understanding of process control methodology to minimize reactive quality checks.
• Perform process capability studies, DOE, and statistical process control analysis.

Continuous Improvement and Best Practices:

• Lead and support structured problem-solving activities (Kaizens, A3s, etc.).
• Identify high-performing assets and replicate best practices across operations.
• Evaluate and implement process improvements for production operations.

Training and Workforce Development:

• Train and educate employees on process integrity, control, and best practices.
• Develop and maintain technical training programs and trouble shooting guidelines.
• Support onboarding and ongoing training for new and existing employees.

Equipment and Reliability:

• Support equipment upgrades, retrofits, and reliability initiatives.
• Partner with Maintenance and operations to improve equipment uptime and performance.
• Manage process-related risks and highlight potential issues proactively.

Project and Capital Support:

• Determine technical and economic feasibility of process improvements and new programs.
• Develop capital estimates for new products or equipment investments.

Safety and Compliance:

• Perform all work in accordance with established OSHA, EPA and Safety Regulations.
• Participate in safety programs and reinforce compliance standards.
• Support a strong safety culture and Human Performance Initiatives.

Additional Responsibilities:

• Miscellaneous duties as directed by leadership.

Candidate Qualifications:

• B.S. degree in Engineering – preferably with concentration in plastics/material science, or, in the absence of a plastics degree a minimum of 5 years engineering experience in extrusion, thermoforming processes or plastics processes.
• Strong skillset in sheet extrusion and inline thermoforming.
• Working knowledge of statistical process control, design of experiments and quality systems.
• Background in continuous improvement process and principles – 5-10 years of prior experience participating in and preferably leading focused improvement teams is a must.
• Supervisory experience required – directing work, coaching, managing performance and development; Ability to coach and train at all levels in the organization.
• Experience working within a team environment, and experience in motivating, and leading current and new employees.
• Adherence and consistent compliance to all food/BRCGS standards and regulations.
• Normal dexterity & weight-lifting requirements (requires extensive walking, bending, reaching, pushing, pulling, climbing and lifting to 30 pounds).
• Work environment: This position will spend approximately 80% of the time in a production floor environment of a manufacturing plant. During time spent in the manufacturing plant floor, this position is subject to moderate noise levels, high and low temperatures and other standard elements of a manufacturing environment.

What You'll Get From Us

With safety as our top priority and a commitment to employee well-being an important focus, we offer comprehensive and competitive benefits that include medical, dental and vision insurance as well as a variety of other well-being resources focused on mental, physical and financial health. Specific benefits and well-being programs may vary depending on where you work.

Community Engagement

At Novolex, giving back to the local communities that support us is important. Our Focused Giving Program prioritizes support for organizations whose missions promote sustainability initiatives or address food and hunger needs. We also encourage facility level support of activities in the communities where our employees live and work.

Training and Development

We offer constant opportunities for advancement. From skills development to advanced education programs, training and development programs and courses are available through MyLearning. Programs include company and industry training curricula, support for formal education through the Tuition Reimbursement Program (Non-Union), and a Learning Management System that supports and enhances employee skills at all levels of the organization.

Novolex is committed to providing equal employment opportunity in all employment practices, including but not limited to selection, hiring, promotion, transfer, and compensation to all qualified applicants and employees without regard to age, race, color, national origin, sex, pregnancy, sexual orientation, gender identity, religion, handicap or disability, genetics, citizenship status, service member or veteran status, or any other category protected by federal, state, or local law. Any individual who, because of his or her disability, needs an accommodation in connection with an aspect of the Company's application process should contact [e-mail].