Process Engineer

Westlake; Salisbury (NC); On-site; USD 70,000 - 95,000; Full time

Job summary

Westlake's Salisbury, NC facility seeks a Process Engineer to champion process engineering initiatives across polymer extrusion and related production to maximize safety, productivity and efficiency.

You will partner with operations teams, drive continuous improvement, and implement data-driven solutions while traveling up to 10% to support other Westlake sites.

Qualifications

• Minimum 3–5 years of functional and hands-on process engineering experience in polymer injection molding & extrusion.
• Bachelor’s degree (B.S.) from ABET-accredited university in Mechanical, Chemical, Materials or Industrial Engineering.
• Strong ability to collaboratively solve problems and make data-driven decisions.
• Ability to collaborate across R&D, Manufacturing, and suppliers to develop new products and processes.

Responsibilities

• Ensure all activities are conducted safely and professionally and hold others accountable.
• Partner with R&D and Manufacturing to leverage gated processes for new products and ideas.
• Assist in capital equipment budget planning and project specifications.
• Interface with customers and stakeholders to plan and develop new products and solve production issues.
• Analyze data using statistical software and communicate results clearly; support trials on production equipment.

Skills

Data-driven decisions

Leadership

Problem solving

Communication

Root cause analysis

Education

ABET-accredited B.S. in Mechanical/Chemical/Materials/Industrial Engineering

Tools

DOE

DMAIC

Fishbone

5-Why

FMEA

Statistical analysis

Job description

We are in search of a Process Engineer to champion process engineering at the Salisbury, NC composite siding and trim manufacturing facility. The Process Engineer will be at the forefront of identifying, formulating, and spearheading a range of manufacturing engineering initiatives at their facility to maximize safety, productivity and efficiency. Personal and professional desire to drive continuous improvement and achieve operational excellence is critical to success in this role. You will closely interface with all operations teams, including production, quality, formulation, capital engineering, and product development. The nurturing, development and sustainment of close professional relationships is necessary to achieve the goals of the organization.

*Must be currently residing in or near Salisbury, NC, or willing to relocate to the area. *

*Must be willing to travel up to 10% to support other Westlake sites. *

DUTIES AND RESPONSIBILITIES

May include, but are not limited to, the following:

• Ensure that all activities are conducted in a safe and professional manner, and hold others accountable to the same level.
• Partner with R&D and Manufacturing in leveraging gated processes to bring new products, concepts and ideas to market.
• Assist in capital equipment budget planning and specifying to improve on existing production techniques and to develop new products and production methods.
• Interface with internal and external customers and stakeholders to strategically plan and develop new products and solve a variety of production related issues.
• Analyze data using statistical software and communicate results into easy to understand formats.
• Help develop, trial and implement new material compounds to meet productivity and business objectives.
• Continuous improvement of production processes to improve rates, properties, densities, reduce scrap, etc. by utilizing lab equipment and coordinating trials on pilot and production extrusion equipment.
• Develop collaborative relationships with suppliers to stay abreast of new machinery and/or raw materials.
• Retain samples and controls for production and sales as requested.
• Continually update stakeholders on status of projects through email, phone and meeting participation.
• Maintain electronic records of compound formulations and physical/thermal properties of profiles.
• Assist in development and testing of projects not directly related to extrusion, i.e. print rolls, heat transfer rolls, injection molding, etc.
• Calculate formulation costs and costs of material in extruded parts for management’s evaluation in new and existing parts.
• Attend trade shows, classes and training seminars to keep skills up to date and learn about new equipment, chemicals, new processes related to our industry.
• May serve as technical representative in trade association meetings, i.e. SPE, PIA, AAMA and NFRC, etc.
• Ensure compliance with federal and state safety and environmental regulations.
• Maintain constructive working relationship with all employees and supervisors/managers.
• Perform other duties as assigned to satisfaction of your reporting manager.

EDUCATION, EXPERIENCE AND QUALIFICATIONS

Job Qualifications:

To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

Education:

Bachelor’s degree (B.S.) from ABET accredited university in Mechanical, Chemical, Materials or Industrial Engineering.

Experience:

Minimum 3 to 5 years of functional and HANDS-ON process engineering experience preferably within polymer injection molding & extrusion processes or other physical/chemical production environments.

Skills:

Exceptional ability to collaboratively solve challenging problems is a must. Demonstrated ability to make data driven decisions as a team to identify root cause of production issues is required. Must be able to organize data, people and tasks; possess leadership skills; have a strong working knowledge of our products and possess problem-solving skills and conflict resolution skills. Ability to interpret an extensive variety of technical instructions in mathematical or diagram form and deal with several abstract and concrete variables. Ability to define problems, collect data, establish facts, draw valid conclusions, and build consensus amongst a diverse technical and operational team.

Knowledge of the manufacture, testing, analysis and application of Polymer chemistry.

Six sigma green/black belt and knowledge of DOE, DMAIC, Fishbone, 5-Why, FMEA, statistical analysis, etc. is preferred.

Communication:

Effectively communicate with all levels of employment both verbally and in writing. Exceptional interpersonal skills and demonstrated ability to build collaborative working relationships across a diverse organization are critical to success in this role.

PHYSICAL DEMANDS

While performing the duties of this job, the employee is regularly required to sit. The employee frequently is required to stand; walk; use hands to touch, handle, or feel; reach with hands and arms; and talk or hear. The employee is occasionally required to stoop, kneel, crouch, or crawl. The employee must regularly lift and/or move up to 10 pounds, frequently lift and/or move up to 25 pounds, and occasionally lift and/or move up to 50 pounds. Specific vision abilities required by this job include close vision, distance vision, depth perception, and ability to adjust focus. May require travel up to 10% of the time. Incumbent must be able to travel.

WORK ENVIRONMENT

The noise level in the work environment is usually moderate in the office. The position requires the incumbent travel to the various manufacturing facilities as much as 10% of the time. The work environment at the facilities can include excessive noise levels, exposure to weather elements, working around or adjacent to moving and mobile equipment and climbing ladders. Appropriate personal protective equipment including hearing protection, steel toe shoes, safety glasses and/or hard hats may be required while working in a facility.