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Chester, SC

Senior Process Engineer

Senior Process Engineer

FPC of Decatur

FPC of Decatur

Job Description:

The purpose of this job is to optimize the manufacturing processes, and ensure efficiency, quality, and compliance. This position will act as the Senior Process Technical Manager/Expert at the New IKO Fiberglass Mat Plant in Chester, South Carolina. The plant will be a new greenfield plant, which is targeted to start up Q1-Q2 of 2025. This position will be part of the operational readiness team while the plant is being built and then will be the process technical leader working direction with the production manager and the rest of the management team. This position will report directly to the Plant Manager.

Job Responsibilities:
•This position will have one junior process engineer as a direct report.
•Develop and implement manufacturing strategies and processes to optimize efficiency, reduce costs, and improve product quality.
•Collaborate with cross-functional teams, including design engineers, quality engineers, and production personnel, to ensure smooth production operations and timely delivery of products.
•Lead and participate in process improvement projects, utilizing Lean Manufacturing and Six Sigma methodologies to identify and eliminate waste, improve productivity, and enhance product quality.
•Evaluate existing manufacturing processes and equipment, identifying opportunities for improvement and implementing changes to enhance efficiency and productivity.
•Conduct root cause analysis and implement corrective actions to resolve production process upsets to include creating corrective actions to prevent upset from occurring in the future.
•Develop and maintain manufacturing documentation, including work instructions, process flow charts, and standard operating procedures (SOPs).
•Train and mentor junior process engineers, production supervisors, and A level operators providing guidance and support in their professional development.
•Stay updated with the latest advancements in manufacturing technology, processes, and industry best practices, and implement relevant changes to improve manufacturing processes.
•Collaborate with suppliers to ensure the availability of quality materials and components and resolve any supplier-related issues that may affect production.
•Ensure compliance with regulatory requirements and industry standards in manufacturing processes. Behaving continuously and consistently with the IKO Core Values; Sharing Knowledge, Integrity, Long-Term thinking, Performance, Humility, and Agility.
•All other duties as assigned.

Required Qualifications:
•Ideal candidates will have 8-10 years of hands-on process engineering experience in a manufacturing environment, preferably in a senior or technical leadership position.
•The ideal candidate would also have wet formed fiberglass mat process or equivalent experience.
•Bachelor's degree in chemical or mechanical engineering or a related field. A master's degree is preferred.
•Proven track record of implementing process improvement initiatives and driving operational excellence.
•Familiarity with SPC (statistical process control) is a requirement.
•Strong knowledge of manufacturing principles, practices, and standards.
•Proficient in Microsoft Office (Excel, Word, PowerPoint)
•Strong detailed oriented technical writing skills.
•Ability to lead junior process engineers, co-op, or interns while having strong teaching and develop skills.
•Certification in Lean Six Sigma is preferred.
•Excellent customer service focus and results oriented.
•Greenfield or Brownfield start-up experience preferred.

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