SUMMARY:

The Manufacturing Engineer IV is responsible for the quality and efficiency of existing production processes while operating in a safe manner. This position will include involvement between Engineering, Operations, Quality, and Research and Development teams. This role uses data, process expertise, and structured problem-solving methods to identify risks, resolve complex manufacturing issues, and lead sustainable improvements. The engineer partners daily with production employees and plant leadership to implement changes that meet customer, regulatory, and business requirements.

ESSENTIAL DUTIES AND RESPONSIBILITIES

• Maintain and/or improve first pass acceptance (FPA) of assigned processes.
• Report FPA on a weekly basis with reasons, disposition and corrective action to any quality/production related issues that impact the department/site FPA target.
• Assigned with the responsibility and authority to ensure customer requirements are met regarding the selection of special characteristics.
• Propose disposition of off-specification, process-deviated, and process-modified materials to quality review board (QRB).
• Review process worksheets and develop action plans when unplanned deviations occur in process.
• Troubleshoot processing equipment issues. Provide input for permanent fixes and/or preventive maintenance schedules.
• Investigate customer complaints using root cause analysis techniques. Develop and implement process improvements to address root causes.
• Review specifications for new customers and raw materials.
• Initiate and implement improvements to process with regards to quality and mistake-proofing using South Plainfield approved methods (ie PMF).
• Identify and monitor the critical characteristics of quality (CTQ) and include them in process worksheets and control plans. Analyze and establish control limits for CTQ.
• Supports implementation of capital projects developed by Plant Manager or Production Managers
• Lead and participate in Management of Change (MOC), HazOp, and Pre-Startup Safety Review processes as needed.
• Lead or be part of multifaceted teams to address safety, environmental, production, and quality issues for area of responsibility, as well as for other areas of the site.
• Actively participate and/or lead Job Safety Analysis teams.
• Prepare for and participate in UL and customer visits, audits, and inquiries regarding existing processes.
• Develop and maintain Control Plans, FMEA for products.
• Work with R D on Ames Stage and Gate process for innovative products being introduced into production. Track and report the scale up deliverables as per Ames S&G procedure.
• Maintain up-to-date documentation for existing processes, (ie. process worksheets, standard operating procedures, references, forms, etc.). Train production supervision personnel on updated documentation.
• Maintain up-to-date Navision documentation for existing products, including bill of materials and recipe information.
• Track process yields and variances from standard cost. Propose and implement improvements as necessary.
• Understand process capacity and suggest improvements to eliminate bottlenecks.

REQUIREMENTS AND QUALIFICATIONS

• Bachelor's degree in Chemical Engineering, Chemistry, or other related Science field.
• 5 - 10 plus years of experience in a chemical manufacturing plant.
• Certified Six Sigma Green belt.
• Proficient in Microsoft Excel, PowerPoint, and Word.
• Proficient in Minitab or other statistical analysis tools.
• Experience with an MRP system, Knowledge of Microsoft Navision preferred.
• AutoCAD experience a plus.
• Able to scale-up new production processes along with R D.
• Generate specifications for new products based on process data.
• Experience in dealing with operations personnel. Ability to lead and supervise plant personnel when required.
• Experience working and troubleshooting manufacturing equipment. With an ability to operate production equipment when needed.
• Ability to deal directly with supervisory personnel, department managers, and upper management.
• Ability to present and communicate results of analysis and research on products and/or processes to Senior Company management.
• Effectively lead a root cause analysis investigation for customer complaints, product issues, process drifts.
• Excellent problem-solving skills and understanding of methodologies.
• Project management experience, projects ranging in the $25-150K range
• Solid knowledge of quality management systems/ISO 9000 requirements.
• Capability to plan, organize, follow-up and make decisions based on results without major guidance. Ability to analyze data and make recommendations.
• Must be able to work efficiently and effectively striving for continuous improvement.
• Ability to learn and lead in multiple departments as the process expert.
• Excellent verbal and written communication skills, direct in dealing with others.

TRAVEL REQUIREMENTS

• Less than 10% travel

COMPETENCIES

Strong attention to detail Great organizational skills and follow-up Strong decision making Review data and make decisions Strong ability to influence

• This job description indicates the general nature and level of work expected of the incumbent.

It is not designed to cover or contain a comprehensive listing of activities, duties, or responsibilities required of the incumbent. Incumbent may be asked to perform other duties as required.

Pay:

$95,000.00 - $110,000.00 per year

Benefits:

401(k) 401(k) matching Dental insurance Flexible spending account Health insurance Life insurance Paid time off Parental leave Professional development assistance Referral program Retirement plan Tuition reimbursement Vision insurance

Education:

Bachelor's (Required)

Experience:

Chemical Manufacturing Plant:

5 years (Preferred)

Microsoft Dynamics Navision:

5 years (Preferred)

AutoCAD:

5 years (Preferred) Root cause analysis: 5 years (Required)

ISO 9001

5 years (Preferred) Project management: 5 years (Preferred)

License/Certification:

Lean Six Sigma Green Belt (Required) Ability to

Commute:

South Plainfield, NJ 07080 (Required)

Work Location:

In person