Process Engineer III

Toray Advanced Composites (TAC) is a leading supplier of advanced composite materials for the aerospace, sporting goods, motor sport, and industrial markets. You will find our thermoset composite products on nearly every satellite, space launch vehicle, unmanned aircraft, military, and commercial aircraft in production today. TAC also provides composite materials to industrial and recreational applications including mountain bikes, medical prosthetics, and sports equipment.

Our thermoplastic prepregs, known in the industry as Cetex, are found in a wide range of commercial and military aircrafts, including large wing structures and interior applications like seats and galleys. Our Cetex products are available in unidirectional tape or fabric form in a variety of engineered thermoplastic resins including PAEK, PEKK, PEEK, PPS, PEI as well as a full line of performance thermoplastics including Nylon, PET, HDPE, and PP.

SUMMARY OF FUNCTIONS:

The Process Engineer III will be accountable and responsible for technical ownership of the production process. The engineer will be responsible for the complete process control, technical oversight of a continuous production process, to ensure maximum up-time, with highest efficiency, excellent quality to provide mentorship and technical guidance to other process engineers. Additionally, the engineer will lead multiple departmental efforts with new product development and production integration. This is a hands-on process engineering role, and will require ingenuity, flexibility and problem-solving capabilities using RCCA Lean Six Sigma or any other technical tools or data to solve the problem. A primary objective is to maintain, improve and contribute to the consistency of the production processes, recommend and execute upgrades to process control, and take leadership in production/equipment upgrades. The process engineer will be experienced in the methodology and techniques to produce continuous reinforced composite materials.

Please note roles and responsibilities are subject to change with or without advanced notice.

MAJOR DUTIES AND REQUIREMENTS:

• Responsible for executing all process engineering activities across a broad range of processes, ranging from manufacturing, process control/optimization, scrap reduction, and to support and lead engineering trials

• Recognizes, implements, and troubleshoots tools by providing root cause and corrective actions (RCCA) to problems associated with impregnation or batch mixing manufacturing processes.

• Lead and support in establishing and measuring process performance standards associated with quality, waste/throughput.

• Contributes and executes to operational reviews and other efforts leading to safety, process improvements and cost reduction activities.

• Supports and provides feedback in investigations and execute RCCA in operational non-conformances and customer related issues.

• Support plans, leads and executes capital projects and process improvement activities.

• Supports and participates in customer site audits/qualifications and visits at Toray.

• Support targeted projects which include defining and documenting product and processing parameters, capability, cost reductions and manufacturing.

• Evaluates, troubleshoots, and solve quality processes, safety and process led improvements

• Documenting and creating manufacturing processes and methods per AS9100 (or equivalent) quality system

• Creates and provides training for manufacturing Configurations, Bills of Materials, Routers, Work Instructions, SPC/SQC, and Control Plans using manufacturing engineering best practices.

• Works with and leads all related functions including Manufacturing, Maintenance, Process Technology, R&D, Quality Assurance and Receiving/Shipping to achieve the company's objectives

• Must be able to support multiple projects.

• Assists in responsibility for the safety and environmental issues associated with the manufacturing processes and equipment.

• Supports process engineering and operation department leads/managers in his/her functional activities, and performs other duties as assigned.

• Available and willing to work during off hours when needed.

EXPERIENCE AND/OR EDUCATION REQUIREMENTS:

• Bachelor’s Degree in material science, engineering, chemical, mechanical or related field

• More than seven years of experience working in composite materials, aerospace manufacturing industry.

• Mentorship, training or supervision experience preferred.

• In depth understand of statistical analysis, process control, project management, RCCA and FMEA

• Lean and Green Belt or Black Belt Six Sigma training (certification is preferred)

• Root Cause, PFMEA, Statistics & SQC/SPC

• Has  in depth understanding of business ERP system (Microsoft Dynamic D365 or similar)

• Must be able to communicate clearly (written and verbally) in English

• Able to work and communicate with interdisciplinary teams and the leadership team.

• Maintain work areas in a neat, orderly and safe manner

• Follow safety procedures for PPE (personal protection equipment)

• Previous experience with composite part manufacturing and/or composite impregnation processes are preferred.  Specifically in thermoset/thermoplastic resin systems with carbon and/or glass tape/fabrics.

Salary:  $105,000 - $130,000

Toray Advanced Composites employment practices offer equal employment opportunity and does not discriminate against its employees or applicants because of race, color, religion, sex, pregnancy, national origin, ancestry, age, marital status, physical or mental disability, medical condition, sexual orientation, or any other basis prohibited by law.  Equal employment opportunity will be extended to all persons in all aspects of the employer/employee relationship, including recruitment, hiring, training, promotion, transfer, discipline, layoff, recall, and termination