Process Engineer – Lean & Automation for PVC Plant

Westlake Pipe & Fittings; Greensboro (GA); On-site; USD 85,000 - 120,000; Full time

Benefits offered by this job

Benefits day 1

4% 401k match + 3% employer contrib.

Quarterly incentive plan up to 8%

Fitness reimbursement

Educational assistance

Employee assistance program

Job summary

Westlake Pipe & Fittings in Greensboro, GA seeks a Process Engineer to lead daily plant operations, optimize production, reduce downtime, and improve material usage. You will provide technical problem solving, develop engineering procedures, and support capital projects.

The role requires 3–10 years in manufacturing, experience with PVC processing/extrusion, and strong CI/engineering skills. Onsite work Mon-Fri with travel and leadership responsibilities.

Qualifications

• B.S. degree (or equivalent) in Electrical, Mechanical, or Material Science Engineering, plus 3-10 years of experience of manufacturing work experience.
• Experience with high volume, continuous manufacturing environment required.
• Experience in HSE regulatory compliance/engineering preferred.
• Experience in PVC processing and Extrusion highly desired.
• Fundamental understanding of OT networks, industrial controls and automation highly desired.
• Process Engineering / Manufacturing Engineering / CI skills and expertise.
• A results-oriented problem solver with an analytical approach.
• Excellent verbal & written communication.
• A hands-on individual with the ability drive results through others.
• Six sigma green/black belt and knowledge of DOE preferred.

Responsibilities

• Lead and direct technical activities necessary to solve problems encountered in any part of the facility.
• Develop & maintain process guidelines (SOP/SOC) and training programs for the integration of new products and systems.
• Conduct data analysis of scrap, downtime, line rates, and material usage.
• Prepare charts and reports to assist the plant team to make data driven decisions to improve results.
• Continually strive to reduce process variation to ensure consistent product quality and adherence to standards.
• Lead cost reduction initiatives through materials, product, and process improvements.
• Facilitate brainstorming sessions and develop action plans for the Westlake Improvement Process (WCI) and Profit Improvement Process (PIP).
• Utilize Lean, Six-Sigma, 5S/6S, TPM, Kaizen, VSM, DOEs, and FMEAs.

Skills

Process engineering

Manufacturing engineering

Six Sigma

DOE

PLC programming

Automation

Lean Manufacturing

Kaizen

Data analysis

Education

Bachelor's degree in Electrical, Mechanical, or Materials Science Engineering

Tools

PLC programming

FMEAs

OT networks

Automation software

Job description

Westlake Pipe & Fittings, a Westlake division (NYSE:WLK), is one of the largest polyvinyl chloride pipe and fittings manufacturer in North America. With 23 manufacturing and distribution locations, the company supplies gasketed, solvent weld and restrained joint pipes and a wide range of fittings for a diverse list of markets including municipal water and sewer, plumbing, water well, pool and spa, and agricultural and turf irrigation. Westlake Pipe & Fittings is an industry leader in product development with Certa-Lok® spline-lock technology and product systems that are focused on building A Better Foundation. To learn more, visit the website at WestlakePipe.com and follow us on LinkedIn and Facebook.

Benefits day 1, 4% 401k match plus 3% annual employer contribution, quarterly incentive plan up to 8%, plus programs for fitness reimbursement, educational assistance, and employee assistance. Take your career to the next level and join us now!

Summary

The Westlake Process Engineer will be heavily involved in the daily operations of the facility and is a key member of the plant leadership team. Lead the manufacturing program for plant output optimization, down-time reduction, scrap reduction, process control, and material usage optimization. Provide problem solving consultation, develop engineering procedures, and support for capital projects.

Duties And Responsibilities

• Support operations by leading and directing technical activities necessary to solve problems encountered in any part of the facility.
• Develop & maintain process guidelines (SOP/SOC) and training programs for the integration of new products and systems.
• Conduct data analysis of scrap, downtime, line rates, and material usage. Prepare charts, and reports to assist the plant team to make data driven decisions to improve results.
• Continually strive to reduce process variation (improve process capability) to ensure consistent product quality and adherence to manufacturing and agency standards.
• Lead cost reduction initiatives through materials, product, and process improvements. Facilitate brainstorming sessions and develop action plans for the Westlake Improvement Process (WCI) Profit Improvement Process (PIP). Examples include activities to reduce utilities consumption, cycle times, scrap, downtime, material usage variance, and direct labor.
• Utilize a variety of continuous improvement tools such as: Lean Manufacturing/Toyota Production Systems, Six-Sigma, 5S/6S, Total Productive Maintenance, Kaizen Events, Value Stream Maps, DOEs, FMEAs, Advanced Problem-Solving, etc.
• Participate in updating of manufacturing standards as a result of performance improvements.
• Develop work cell layouts in an effort to optimize material flow and support 5S and visual management initiatives.
• Initiate new equipment and technologies to maintain the company’s competitive advantage; including detailed scope definitions with the plant (capabilities, throughput, and equipment controls including function block diagrams, process parameters, and data acquisition requirements), RFQ documents, and execution timeline plans (including facility preparation, installation, HSE, training, production ramp-up, etc.).
  
  

EMPLOYEE RELATIONS

• Ensure own conduct and that of direct reports is in accordance with Westlake Code of Business Ethics and the Workplace Discrimination/Harassment Policy
• Communicate with employees, plant and supervisory staff as required.
• Build participative working relationships with plant and management personnel.
• Comply with company rules, regulations and policies as stated in the Employee Relations Manual and/or Employee Handbook.
  
  

Education, Experience And Qualifications

• B.S. degree (or equivalent) in Electrical, Mechanical, or Material Science Engineering, plus 3-10 years of experience of manufacturing work experience.
• Experience with high volume, continuous manufacturing environment required.
• Experience in HSE regulatory compliance/engineering preferred.
• Experience in PVC processing and Extrusion highly desired.
• Fundamental understanding of OT networks, industrial controls and automation highly desired.
• Process Engineering / Manufacturing Engineering / CI skills and expertise.
• A results-oriented problem solver with an analytical approach.
• Excellent verbal & written communication.
• A hands-on individual with the ability drive results through others.
• Six sigma green/black belt and knowledge of DOE preferred.
• Knowledge of mistake-proofing sensor technology and PLC programming is desirable.
• Must be able to work Monday - Friday, 6:30am-4pm (possibly working 45-50 hours/week based on business needs.)
• Must be able to commute daily into our Greensboro, GA plant. This is a fully onsite role.
• Must be able to travel for 1-4 weeks per year. Likely 3-4 weeks per year in the first couple of years.
  
  

PHYSICAL DEMANDS

While performing the duties of this job, the employee is frequently required to sit; 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, or crouch. 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, peripheral vision, depth perception, and ability to adjust focus.

WORK ENVIRONMENT

This is a hands-on position. The noise level in the work environment is usually moderate as half of the time is based in an office and half of the time will be required in the operating units which can require usage of PPE including safety glasses, hearing protection, etc. May also result in exposure to outside elements with hot and cold temperatures and may require usage of stairs and elevators. Travel including air travel or auto travel may occasionally be required.

Westlake offers you the potential to enrich your work life and career experience in an entrepreneurial environment. We work together to enhance peoples lives through our products and presence in the communities in which we operate.

Westlake is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to any characteristics protected by applicable legislation.