Process Engineer
Process Engineer
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$ 95000 - 115000
1 Vacancy
Job Description
Job Description
REHAU is seeking an experienced Process Engineerto join our manufacturing team in Cullman this role you will be responsible for optimizing extrusion processes driving continuous improvement initiatives and ensuring quality safety and efficiency across operations. Youll collaborate closely with production QA maintenance and R&D while also supporting new product development and equipment implementation.
This position offers the opportunity to travel both domestically and internationally including working with our technical team internationally and key suppliers.
Key Responsibilities
- Process Optimization & Troubleshooting
- Analyze and improve extrusion parameters to enhance throughput reduce waste and maintain product specifications.
- Identify root causes of process deviations and defects; implement corrective and preventive actions.
- Quality Assurance Support
- Collaborate with QA to ensure products meet dimensional mechanical and visual standards.
- Support SPC capability studies and quality audits.
- New Equipment & Process Implementation
- Lead installation commissioning and validation of new equipment tooling and auxiliary systems.
- Develop and execute process qualification protocols and ensure smooth integration into operations.
- Time Studies & Cost Analysis
- Conduct time/motion studies to identify inefficiencies and optimize labor/machine utilization.
- Perform cost calculations for material cycle times energy and labor to support continuous improvement and investment decisions.
- Documentation & Reporting
- Maintain accurate records of process settings trials and metrics.
- Prepare technical reports and presentations for management audits and cross-functional teams.
- Continuous Improvement & Technology Integration
- Lead/participate in Lean Six Sigma and Kaizen initiatives.
- Support automation sensors and data acquisition systems for real-time monitoring/control.
- Training & Support
- Train operators and technicians on SOPs troubleshooting and best practices.
- Provide technical support for daily operations and improvement projects.
- Safety & Compliance
- Ensure compliance with OSHA regulations REHAU policies and ISO standards.
- Promote a strong culture of safety and environmental responsibility.
Key Capabilities & Skills
Technical Skills
- Strong knowledge of polymer materials and extrusion behavior.
- Proficiency with extrusion equipment (extruders dies calibration tables haul-offs).
- Familiarity with PLC/SCADA systems and data analysis tools.
- Understanding of rheology heat transfer and fluid dynamics.
Analytical & Problem-Solving
- Strong troubleshooting/root cause analysis.
- Ability to interpret process data charts and SPC/DOE results.
- Experience with FMEA and risk mitigation.
Project Management
- Ability to manage multiple projects and trials.
- Skilled in cross-functional collaboration and communication.
Soft Skills
- Strong communication and interpersonal skills.
- Detail-oriented proactive and able to work independently and in teams.
Educational Background Required:
- Bachelors Degree in Chemical Engineering Mechanical Engineering Polymer Science & Engineering Materials Engineering or Industrial Engineering (with relevant experience).
- 510 years of professional experience in process engineering extrusion or related manufacturing fields.
Preferred:
- Masters Degree in Polymer Engineering Process Engineering or Manufacturing Systems Engineering.
- Coursework/experience in thermoplastics extrusion fluid mechanics and heat transfer highly beneficial.
Certifications (Preferred Not Required)
Technical & Industry
- Certified Manufacturing Engineer (CMfgE) SME
- Six Sigma Green/Black Belt
- Lean Manufacturing Certification
- Extrusion Process Training (Polymer Center of Excellence Penn College SPE etc.)
Quality & Compliance
- ISO 9001: Quality Management Systems
- ISO 14001: Environmental Management Systems
- OSHA Safety Training
Software & Tools
- PLC Programming & Automation Systems
- SPC Tools
- CAD/CAM or Simulation Software (SolidWorks Moldflow etc.)
Compensation
- Salary range: $95000 $115000 annually based on experience and qualifications.
Travel
- Occasional travel required both domestic and international to meet with suppliers and to collaborate with REHAUs technical team in Germany.
Employment Type
Full-Time
