Senior Process Engineer

The AZEK Company; Wilmington (OH); On-site; USD 90,000 - 130,000; Full time

Job summary

The AZEK Company in the United States seeks a Senior Process Engineer to support day-to-day extrusion operations while leading long-term continuous improvement initiatives.

You will troubleshoot, optimize process reliability, and collaborate with maintenance and manufacturing teams to improve OEE, cost, safety, and quality through Lean and Six Sigma methodologies.

Qualifications

• Bachelor’s degree in engineering (Mechanical, Chemical, Manufacturing, or related field).
• Minimum of 5+ years of experience in manufacturing with hands-on process engineering experience.
• Proficiency in process optimization tools, data analysis, and statistical software.
• SolidWorks experience for design and modification purposes.
• Strong problem-solving, cross-functional leadership, and collaboration skills.

Responsibilities

• Provide hands-on technical support for extrusion processes, resolving issues related to process flow, equipment functionality, material inconsistencies, and quality deviations.
• Investigate daily operational challenges using root cause analysis and Six Sigma methodologies.
• Lead cross-functional teams to design, develop, and implement process improvements to increase productivity and safety.
• Develop and implement SOPs and protocols for equipment to ensure long-term efficiency.
• Recommend capital investment projects and manage capital spending for upgrades.
• Lead initiatives integrating automation and digital tools to optimize processes and sustain improvements.
• Collaborate with Maintenance and Manufacturing to ensure equipment uptime and quality.

Skills

Process optimization

Data analysis

Statistical software

Communication

Cross-functional teamwork

Education

Bachelor’s degree in engineering

Tools

Minitab

JMP

SolidWorks

Job description

As a Senior Process Engineer, you will play a dual role, supporting day-to-day manufacturing operations while spearheading long-term continuous improvement initiatives. Your immediate focus will be troubleshooting and optimizing extrusion processes with an emphasis on improving process equipment reliability and Overall Equipment Effectiveness (OEE). By addressing these key areas, you will drive significant gains in operational efficiency and equipment performance.

In this role, you will lead strategic process enhancements that align with James Hardie's manufacturing goals, ensuring both short-term operational success and long-term innovation. Your expertise will be critical in identifying and resolving inefficiencies in extrusion processes, reducing downtime, and maximizing equipment utilization. With a proactive approach to sustainable improvement, you will combine technical problem-solving with process optimization, contributing to James Hardie's commitment to operational excellence and continuous improvement in line with the company's Core Values.

Essential Duties and Responsibilities

Direct Manufacturing Support

• Provide hands‐on technical support for extrusion processes, resolving issues related to process flow, equipment functionality, material inconsistencies, and quality deviations.
• Investigate and address daily operational challenges, including equipment failures, quality non‑conformance, safety concerns, using root cause analysis and Six Sigma methodologies.
• Collaborate with Maintenance and Manufacturing teams to ensure equipment uptime.
• Troubleshoot and validate new or idled equipment during commissioning, repair, upgrade, or replacement to ensure safe, efficient integration into production and alignment with operational goals.

Long‑Term Strategic Continuous Improvement

• Lead cross‑functional teams to design, develop, and implement process improvements that increase productivity, reduce costs, and enhance safety and quality.
• Analyze process data to identify opportunities for improvement.
• Develop and implement Standard Operating Procedures (SOPs) and protocols for equipment to ensure long‑term consistency and efficiency.
• Recommend capital investment projects, factoring in long‑term risk, cost, and operational benefits, while managing capital spending for upgraded and replacement equipment.
• Lead initiatives integrating automation and digital tools to optimize processes and drive sustainable performance improvements.
• Apply Lean, Six Sigma, and other methodologies to implement innovative solutions that support long‑term operational goals.
• Collaborate with external vendors and stay informed about emerging technologies for future process enhancements.

Quality Control & Compliance

• Implement and refine quality control measures to ensure the consistency and integrity of extruded products.
• Ensure compliance with safety regulations, industry standards, and environmental guidelines in both immediate and long‑term operations.

Communication & Stakeholder Engagement

• Communicate project milestones, process improvements, and technical recommendations to stakeholders through detailed reports and presentations.
• Collaborate with cross‑functional teams, including R&D, Maintenance, Quality, and Production, to align short‑term operational needs with long‑term strategic goals.

QUALIFICATIONS

• Education: Bachelor’s degree in engineering (Mechanical, Chemical, Manufacturing, or related field).
• Experience: Minimum of 5+ years of experience in manufacturing, with hands‑on experience in process engineering, material handling, and mixing‑related equipment.
• Proficiency in process optimization tools, data analysis, and statistical software (e.g., Minitab, JMP, or similar).
• Skilled in the use of SolidWorks for design and design modification purposes.
• Strong problem‑solving skills with a demonstrated ability to resolve immediate production issues while contributing to long‑term improvement initiatives.
• Experience working on continuous improvement projects, preferably using Lean or Six Sigma methodologies.
• Excellent communication and collaboration skills, with a proven ability to lead cross‑functional teams.