Process Engineer

XSYS Global; Morristown (NJ); On-site; USD 95,000 - 125,000; Full time

Job summary

XSYS Global is seeking a Process Engineer to lead development, standardization, and optimization of manufacturing processes in polymer extrusion, compounding, and coating operations. You will work with Operations, R&D, Quality, Maintenance, and Supply Chain to drive efficiency and quality improvements.

Responsibilities include designing improvement initiatives, performing ROI analyses for CapEx, collaborating with vendors on equipment, and maintaining SOPs and process documentation to support

Qualifications

• B.S. in Polymer, Mechanical, Manufacturing or Industrial Engineering. Equivalent experience will be considered.
• 5–10 years of Process Engineering experience in polymer extrusion.
• Experience with multiple feed compounding extrusion is preferred.
• Experience with coating or sheet extrusion is preferred.
• Knowledge of statistical process control, root cause analysis, and data historians.
• ASQ Six Sigma Green Belt, Black Belt, or Quality Engineer preferred.
• Excellent negotiation and interpersonal skills. Able to communicate from shop floor to VP.
• Ability to stay organized while handling multiple priorities.

Responsibilities

• Design, lead, and evaluate process improvement initiatives focusing on safety, quality, throughput, yield, waste reduction, and cost optimization.
• Develop ROI analyses and justify CapEx projects; lead projects from concept through commissioning.
• Collaborate with vendors to specify, source, install, qualify, and optimize new manufacturing equipment and technologies.
• Establish and maintain process control parameters and troubleshooting methods for consistent product quality.
• Support new product development, process scale-up, and commercialization with R&D and Operations teams.
• Create, update, and maintain SOPs, work instructions, and ISO-quality records.
• Lead root-cause investigations and corrective actions for deviations and safety incidents.
• Provide technical guidance and training on best practices and continuous improvement.

Skills

Process optimization

Statistical analysis

SOP development

Cross-functional collaboration

Education

B.S. in Polymer/Mechanical/Manufacturing/Industrial Engineering

Tools

SPC software

Data historians

Job description

XSYS is a global provider of integrated solutions for the flexographic, letterpress and pre-press printing markets, offering photopolymer plate processing systems, sleeves/adapters, and complementary workflow technologies. With a strong focus on customer success, we combine deep technical expertise with service and support to deliver consistent quality and productivity for printers, converters, and trade shops.

Process Engineer

Mission of the role & responsibilities

The Process engineer is responsible for leading the development, standardization, and optimization of manufacturing processes within polymer extrusion, compounding, and coatingf operations. This role establishes processing standards, operating methods, and best practices to ensure safe, efficient, and repeatable production. Working closely with operations, R&D, Quality, Maintenance, and Supply Chain teams, the process Engineer drives operational excellence, supports new product development and commercialization, and identifies continuous improvement opportunities that enhance productivity, quality, safety and cost performance.

Responsibilities:

• Design, execute, and evaluate process improvement initiatives focused on safety, quality, throughput, yield, waste reduction, and cost optimization.
• Develop economic justifications for capital expenditure (CapEx) projects, including return-on-investment analyses, and lead project implementation from concept through commissioning.
• Collaborate with vendors to specify, source, purchase, install, qualify, and optimize new manufacturing equipment and technologies.
• Establish and maintain process control parameters, operating windows, and troubleshooting methodologies to ensure consistent product quality and manufacturing performance.
• Support new product development, process scale-up, and commercialization activities through close collaboration with R&D and Operations teams.
• Responsible for creating, updating, and maintaining process documentation, standard operating procedures (SOPs), work instructions, and records required under the plant's ISO quality management system.
• Lead root cause investigations and corrective action efforts for process deviations, quality issues, safety incidents, and manufacturing inefficiencies.
• Provide technical guidance and training to production, maintenance, and quality personnel on process-related best practices and continuous improvement methodologies.
• Monitor process performance and regularly communicate project progress, risks, and outcomes through formal progress updates and final project reports.
• Support compliance with all environmental, health, safety, quality, and regulatory requirements while promoting a culture of operational excellence and continuous improvement.

Required qualifications

• 5 to 10 years previous Process Engineering experience in polymer extrusion.
• Experience with multiple feed compounding extrusion is preferred.
• Experience with coating or sheet extrusion is preferred.
• B.S. in Polymer, Mechanical, Manufacturing or Industrial Engineering. Equivalent experience will be considered.
• Knowledge of statistical process control, root cause analysis, and data historians
• ASQ certification as a Six Sigma Green Belt, Six Sigma Black Belt, or Quality Engineer preferred.
• Excellent negotiation and interpersonal skills. Must be able to effectively communicate from the shop floor operator to the VP.
• Must have the ability to stay organized while handling multiple priorities.