Senior Process Engineer

Job Summary:

Core Duties

Process Development and Optimization

• Develop refine and optimize TPU extrusion processes in collaboration with existing organizations in internal lab-based development
• Establish and maintain process parameters to ensure consistent product quality
• Lead root-cause analysis and corrective actions for process deviations scrap and downtime.
• Implement continuous improvement initiatives using Lean Six Sigma or similar methodologies.

Technical Leadership Support and Troubleshooting

• Provide day-to-day technical support to production teams for extrusion lines.
• Troubleshoot issues related to melt temperature die design screw configuration cooling and downstream equipment.
• Partner with R&D to scale up new TPU formulations and product designs from lab to production.
• Conduct extrusion trials document results and establish robust manufacturing processes.
• Collaborate with research and development teams as technologies transition to pilot & scale-up environments to ensure successful commercialization.

Quality Safety and Compliance Leadership

• Develop and maintain process documentation including work instructions control plans and standard operating procedures.
• Work closely with Quality to ensure compliance with customer specifications and industry standards.
• Analyze process data to identify trends and drive quality improvements.

Data Performance Analytics and Strategic Improvement

• Monitor key process indicators (KPIs) such as yield scrap rate cycle time and line efficiency.
• Use statistical tools to evaluate process capability and stability.
• Recommend and implement process automation or digital monitoring enhancements.

Basic Qualifications

• Bachelors degree in Chemical Polymer Mechanical Materials Engineering or a related field.
• 6 years of progressive experience in process engineering with strong exposure to polymer films coatings or similar manufacturing environments.
• Deep hands-on expertise with manufacturing equipment including leading equipment optimization upgrades and reliability improvements.
• Proven ability to lead complex troubleshooting efforts applying data-driven methodologies to resolve issues and optimize critical process parameters.
• Advanced proficiency in continuous improvement and problem-solving frameworks with demonstrated project leadership and measurable results.
• Strong analytical capabilities with experience in statistical analysis process capability and hypothesis-driven problem solving.
• Demonstrated leadership in cross-functional collaboration with the ability to influence stakeholders and drive alignment across production quality and R&D teams.
• Experience managing multiple high-impact projects simultaneously in fast-paced manufacturing environments with strong prioritization and execution skills.
• Strategic mindset with a strong attention to detail focused on long-term process sustainability scalability and cost optimization.
• Proven track record of mentoring junior engineers and contributing to team development and technical growth.
• Willingness and ability to travel 2550% to support multi-site operations equipment vendors and scale-up activities.

XPEL is an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive environment for all employees.