Process Engineer

The Process Engineer will be responsible for developing, optimizing, monitoring, and improving extrusion processes to achieve consistent product quality, higher productivity, reduced scrap, and improved machine efficiency.

The role involves process parameter control, troubleshooting, new product trials, tooling/die , dimensional optimization, and continuous improvement.

Key Responsibilities

1. Extrusion Process Management • Set, monitor, and optimize extrusion process parameters such as temperature, pressure, speed, feed rate, cooling, and puller speed. • Develop and maintain standard process parameters for different products, materials, and profiles. • Ensure stable and repeatable extrusion processes. • Monitor production performance and take corrective action for process deviations. • Reduce material wastage, rejection, rework, and process variation. 2. Process Troubleshooting • Identify and resolve extrusion-related defects such as: o Dimensional variation

Surface defects o Die lines o Bubbles/voids o Warpage o Poor fusion o Color variation o Inconsistent thickness o Melt fracture o Scratches and deformation • Conduct root-cause analysis using tools such as 5 Why, Fishbone, Pareto, and 8D. • Implement permanent corrective and preventive actions. 3. Die & Tooling Management • Support die selection, die setting, die trials, and die optimization. • Coordinate with tool-room/die suppliers for die corrections and modifications. • Analyze die performance and identify opportunities to improve output and product quality. • Maintain records of die history, settings, corrections, and performance. 4. New Product & Process Development • Conduct trials for new products, raw materials, formulations, and tooling. • Develop process parameters and establish standard operating conditions. • Prepare trial reports and process validation reports. • Support product development and industrialization activities. • Ensure successful transfer of new products from development to mass production. 5. Productivity & Cost Improvement • Improve extrusion line output and Overall Equipment Effectiveness (OEE). • Reduce cycle time, scrap, energy consumption, and material losses. • Identify bottlenecks and implement process improvement projects. • Drive continuous improvement using Lean Manufacturing, Kaizen, Six Sigma, and TPM methodologies. 6. Quality & Process Control • Work closely with Quality, Production, Maintenance, and R&D teams to resolve quality issues.