Process Engineer 2nd shift

Job Summary:

The Process Engineer is responsible for providing hands-on process improvements in our secure Bolingbrook facility Monday - Friday 2:00pm - 10:00pm using a combination of Engineering and Lean skill sets to support our key performance indicators of Safety, Quality, Delivery, Cost and Innovation.  Responsible for the technical components of quality in card manufacturing and services.  Plans, directs and carries out work flow design and R&D assignments.

Key Responsibilities:

• Drive the advancement of manufacturing operational processes and material replenishment systems to meet client pull demands. 
• Optimize systems, flow creation, equipment performance and resources.  Lead the tactical efforts towards the achievement of the strategic plan objectives.
• Drive the promotion and facilitation of Lean Engineering events supporting the entire value chain.  This position will focus on key cross functional process and system improvements allowing us to accelerate the standardization, stability, and simplification in the manufacturing and key client facing business processes.
• Develop, enhance, and implement systems that increase efficiency and optimize all phases of service or production processes, from design to manufacturing.
• Oversee, and directly participate in, process design projects, and ensure the efficient and safe functioning of all the processes related to producing a product, substance, or service.
• Conduct problem solving exercises, including root cause analysis, corrective action, and preventive action implementation for plant operations.  Utilizing the following:
• Visual Management systems
• Sustainment of 5S
• Set Up Reduction - SMED methodologies
• Waste Reduction
• Optimizing Inventory Control/Kanban System
• Line Balancing and Flow Creation
• Gemba utilization, including leading huddles
• Evaluate existing processes, suggest measures for improvement, and configure manufacturing systems to reduce cost, improve sustainability, boost productivity, quality, and profitability, and develop best practices within the production process.
• Implement methods and process designs, create prototypes, conduct testing, and make necessary modifications where required.
• Consult with suppliers and vendors and make recommendations relating to materials used in the manufacturing process.
• Analyze facility layout, equipment requirements and work flow, and develop plant layouts for improvement of workflow, security and safety.
• Oversee installation and start-up of new equipment and processes.
• Provide technical input to production and clients.
• Develop programs and processes to improve the performance of cards manufactured.
• Perform other related duties as assigned.

Qualifications:

• Bachelor’s degree in an Engineering discipline and/or a combination of college education
• Minimum of 5 years’ experience in manufacturing, process engineering, or quality engineering.
• Process/Manufacturing Engineering experience in an industrial environment.
• Must have proven team leadership / facilitation skill sets.
• Practitioner of Six Sigma concepts (or Six Sigma certifications)
• Computer proficiency and experience with general engineering software solutions.
• Effective written and verbal communication skills.
• Strong practical skills within a Lean manufacturing environment is highly desirable.
• Experience with various manufacturing process technologies. 
• Working knowledge of manufacturing equipment and systems.
• Lives the Continuous Improvement culture and can drive change.
• Passionate about Lean and the attainment of key initiatives.
• Strong data driven process and system methodologies.
• Ability to hold self and others accountable.
• Enjoys plant level, hands-on involvement in the improvement process.

The pay range for this position is $82,000 - $88,000 per year and is eligible for an annual bonus.  Benefits offered to eligible employees include, medical (PPO and HDHP with HSA), dental, vision, paid time off, paid holidays, 401K w/ employer match, short/long term disability, life insurance, healthcare and dependent care flexible spending, EAP, commuter benefits, education assistance, pet insurance, legal, and more.

Job Duties:

• Utilize expertise in current product knowledge to enhance production methods, aiding the company in meeting budgetary objectives and performance targets.
• Employ knowledge of new products to implement production methods and equipment that align with customer requirements.
• Develop innovative solutions to existing manufacturing challenges.
• Evaluate manufacturing processes through the design and execution of test programs, drawing on insights from product design, materials, assembly, and equipment, and consulting with equipment vendors and relevant stakeholders.
• Assist management in decision-making by calculating production, labor, and material costs, reviewing production and new product schedules, and estimating future equipment and tool requirements.
• Coordinate the manufacturing launch of new or revised products, materials, and equipment, ensuring key variables are measured and controlled, providing communication and training to team members, and evaluating results until targets are consistently met.
• Conduct product and process analysis to drive cost reduction, quality enhancement, and efficiency improvement.
• Develop specifications and execute test plans for equipment purchases, collaborating with suppliers to ensure adherence to specifications.
• Collaborate with Production, Quality, and R&D teams to ensure timely delivery of new products and equipment that meet customer requirements.
• Assist in providing process documentation, operating instructions, and overall hand-off actions to key stakeholders for new or revised processes or production equipment.
• Perform additional tasks as assigned.

Qualifications and Skills:       

• Bachelor’s degree in an Engineering discipline and/or a combination of college education
• Must have proven team leadership / facilitation skill sets.
• Practitioner of Six Sigma concepts (or Six Sigma certifications) 
• Process/Manufacturing Engineering experience in an industrial environment.
• Computer proficiency and experience with general engineering software solutions. 
• Effective written and verbal communication skills. 
• Experience with inventory control programs. 
• Strong practical skills within a Lean manufacturing environment is highly desirable. 
• Experience with various manufacturing process technologies. 
• Working knowledge of manufacturing equipment and systems.
• Lives the Continuous Improvement culture and can drive change.
• Passionate about Lean and the attainment of key initiatives. 
• Strong data driven process and system methodologies.
• Ability to hold self and others accountable. 
• Enjoys plant level, hands-on involvement in the improvement process. Highly motivated to learn and understand manufacturing methods and workflows.

Job Specifications: 

• Work performed in a light industrial setting
• Required to lift up to 40 lbs.
• Regularly required to sit, stand and walk about the facility
• Ability to distinguish color variations
• Able to use various measuring devices
• Must be able to work assigned overtime as needed
• Must be able to travel domestically and internationally as needed

The pay range for this position is $82,000 - $88,000 per year and is eligible for an annual bonus.  Benefits offered to eligible employees include, medical (PPO and HDHP with HSA), dental, vision, paid time off, paid holidays, 401K w/ employer match, short/long term disability, life insurance, healthcare and dependent care flexible spending, EAP, commuter benefits, education assistance, pet insurance, legal, and more.