Senior Process Improvement Engineer - 1481

Sp Associates, Inc.; Dalton (GA); On-site; USD 90,000 - 130,000; Full time

Job summary

Sp Associates, Inc. is seeking an experienced Process Improvement Engineer with a strong background in carded needle-punch nonwoven manufacturing and fiber processing. This hands-on role focuses on improving throughput, quality, and efficiency while collaborating with operations, maintenance, and R&D.

You will lead process optimization from fiber preparation to final finishing, use Lean, Six Sigma, and DOE methods, and develop SOPs and control plans to sustain gains.

Qualifications

• Bachelor's degree in Textile Engineering or related technical field.
• Minimum 5+ years in process improvement or manufacturing engineering.
• Hands-on experience in carded needle-punch nonwoven processes.
• Strong fiber processing, carding and needle-punch knowledge.
• Experience with synthetic fibers and blends.

Responsibilities

• Lead process improvement initiatives for carded needle-punch nonwoven manufacturing.
• Optimize processes from fiber prep to finishing and assess fiber properties impact.
• Troubleshoot fiber opening, blending, web formation, and product consistency issues.
• Develop SOPs, work instructions, and control plans for processes.
• Track improvements: downtime, yield, quality, and material utilization.
• Collaborate with Maintenance and Engineering on equipment changes.
• Support new product development and process validation.

Skills

Process improvement

Lean Manufacturing

Six Sigma

SPC

DOE

Root cause analysis

Analytical thinking

Team collaboration

Fabric processing

Education

Bachelor's degree in Textile Engineering

Tools

Nonwoven machinery

Carding equipment

Needle-punch equipment

Job description

We are seeking an experienced Process Improvement Engineer with a strong background in carded needle-punch nonwoven manufacturing and fiber processing. This role will focus on improving the performance, consistency, efficiency, and quality of carded needle-punch nonwoven manufacturing processes. The successful candidate should understand how fiber characteristics and processing conditions affect carding, needle-punching and final nonwoven product properties. This is a hands-on manufacturing position requiring significant interaction with production equipment, operators, technicians, and engineering teams.

Key Responsibilities

• Lead process improvement initiatives for carded needle-punch nonwoven manufacturing processes.
• Optimize processes from fiber preparation and blending through carding, web formation, crosslapping, needle punching, and finishing.
• Troubleshoot issues related to fiber opening, blending, fiber distribution, web uniformity, basis weight, thickness, density, and product consistency.
• Optimize carding and web-forming conditions to achieve consistent fiber distribution, orientation, web weight, and uniformity.
• Optimize needle-punch parameters including needle density, penetration depth, punch frequency, stroke, and line speed.
• Evaluate the impact of fiber type, fiber length, denier, crimp, finish, blend ratios, and recycled content on manufacturing performance.
• Conduct plant trials and process experiments involving new fibers, fiber blends, equipment settings, and process conditions.
• Identify and eliminate root causes of scrap, defects, downtime, rework, and process variation.
• Analyze manufacturing data to identify opportunities to improve throughput, yield, quality, and material utilization.
• Establish and maintain appropriate process windows, operating standards, and process controls.
• Use structured problem-solving methodologies including Root Cause Analysis, 5-Why, Fishbone, SPC, DOE, Lean, and Six Sigma tools.
• Work with Maintenance and Engineering on equipment modifications and improvements.
• Support new product development and commercialization by establishing repeatable manufacturing processes.
• Develop and maintain SOPs, work instructions, process specifications, and control plans.
• Train and support production personnel on optimized process conditions and standard operating procedures.
• Track and quantify process improvement results, including cost savings, scrap reduction, productivity, yield, and capacity improvements.

Requirements

• Bachelor's degree in Textile Engineering, Chemical Engineering, Mechanical Engineering, Materials Science, Manufacturing Engineering, or a related technical field.
• 5+ years of experience in process improvement, process engineering, or manufacturing engineering.
• Strong hands-on experience in nonwoven manufacturing and fiber processing.
• Direct experience with carded needle-punch nonwoven processes.
• Strong understanding of fiber processing, carding and needle punching.
• Experience working with synthetic fibers and fiber blends, such as polyester/PET, polypropylene, or recycled fibers.
• Experience troubleshooting manufacturing problems directly on the production floor.
• Demonstrated experience improving manufacturing throughput, yield, quality, process capability, and material utilization.
• Strong analytical and problem-solving skills with the ability to use manufacturing data to identify root causes and implement solutions.
• Experience with Lean Manufacturing, Six Sigma, SPC, DOE, and root-cause analysis.
• Strong communication and collaboration skills. Ability to work effectively with Production, Operations, Maintenance, Quality, R&D, and Engineering teams.