Senior Manufacturing Engineer

The Azek Company; Scranton (Lackawanna County); On-site; USD 70,000 - 110,000; Full time

Job summary

An established industry player is seeking a Senior Manufacturing Engineer to spearhead the development and optimization of manufacturing processes for innovative PVC products. This role involves collaborating with cross-functional teams and external suppliers to enhance production efficiency and ensure quality compliance. The ideal candidate will possess a strong background in polymer processing, particularly in high-volume manufacturing environments, and demonstrate exceptional problem-solving abilities. Join a dynamic team that values creativity and continuous improvement, and contribute to exciting projects that shape the future of manufacturing.

Qualifications

• 4+ years of experience in polymer processing or PVC manufacturing.
• Strong knowledge of manufacturing processes and quality improvement tools.

Responsibilities

• Drive process development and optimization for PVC manufacturing.
• Lead projects to improve process monitoring and quality.

Skills

Problem-solving

Process optimization

Statistical Process Control

Root cause analysis

Communication skills

Education

Bachelor's in Mechanical Engineering

Master's in Engineering

Tools

Statistical Process Control (SPC)

Design of Experiments (DOE)

GAGE R&R

PVC extrusion equipment

Job description

The Senior Manufacturing Engineer is responsible for the development, optimization, and validation of processes and systems to support the manufacturing scale up of our PVC Deck and Railing products.

Your primary duties and responsibilities will be:

1. Work within the final assembly manufacturing environment(s) and drive early-stage process development and manufacturing optimization to ensure products meet design intent.
2. Work with and manage external suppliers, conduct DFM reviews, and go onsite as needed.
3. Develop and implement manufacturing processes and measurement methods to meet tight tolerance manufacturing requirements and manufacturing scale up.
4. Lead development of fixtures, equipment, and automation.
5. Interface with contract manufacturers and suppliers.
6. Process evaluations and lead process optimization initiatives utilizing tools such as SPC, DOE, PFMEA, and MSA.
7. Evaluation and continuous improvement of process capabilities.
8. Develop and lead projects to improve process monitoring and quality and reduce costs.
9. Conduct root cause failure analysis and corrective action.
10. Establish sampling and Quality plans.
11. Participate and/or lead risk management activities including product and process FMEA.
12. Support reliability engineering activities.
13. Participate and/or lead validation activities for design, process, or products.
14. Development and qualification of test methods for verifications and validations.
15. Write and execute study protocols, technical reports, manufacturing work instructions (MWI), validations, reports, batch records, design control and other documents as required.
16. Participate on project teams or leading internal teams. Communicate activities across the organization. Interface with various departments to ensure processes and designs are compatible with the manufacturing environment, launch strategy, and Azek’s objectives.
17. Partners with Quality and Regulatory, R&D, and operations to ensure compliance of the manufacturing processes, provide support for regulatory filings, and ensure the robustness of the process and raw materials.
18. Contribute to the development of the facility's capital improvement plan.
19. Coordinate multiple facility-wide shutdowns, collaborating with external contractors and cross-functional teams to ensure seamless execution.
20. Led safety initiatives, margin and capacity improvements, new product development efforts, and reliability/maintenance projects.
21. Develop engineering standards, comprehensive training documentation, and basis of engineering design (BED) documents and standard operating procedures (SOPs).
22. Conduct in-depth time studies to identify process bottlenecks, implementing solutions to optimize efficiency and throughput.

We believe the successful candidate will have:

1. A BS in Mechanical, Manufacturing, or related Engineering field is required, MS preferred.
2. Minimum of 4 years of polymer processing or PVC manufacturing experience using single or twin screw extrusion equipment.
3. Experience in a high-volume manufacturing environment, a strong plus.
4. A track record of generating novel ideas, and out of the box thinker and a true entrepreneurial mindset, a strong plus.
5. Proven ability to solve problems and improve manufacturing processes that use high precision mechanical components.
6. Strong working knowledge and experience in manufacturing processes, process development and validations for finished medical devices.
7. Knowledge of plastics extrusion processing equipment is required.
8. Successful implementation and use of statistical based quality improvement tools such as design of experiments, Statistical Process Control and GAGE R&R.
9. Experience in equipment and automation development.
10. Project leadership in multi-disciplined projects.
11. Experienced in quality system requirements for the building products industry.
12. Proven ability to motivate and lead others, often without direct control, such as suppliers.
13. Self-motivated, team-oriented individual who collaborates and communicates effectively with local and international team members in a cross-functional, multi-cultural, interdisciplinary environment.
14. Comfortable working in an extremely dynamic and fast paced environment, and able to meet aggressive development milestones.
15. Strong verbal and written communication skills.