Process Engineer

Process EngineerLocation: Lancaster County, PAWork Environment: Onsite / Manufacturing FacilityEmployment Type: Full-Time, Direct Hire (Great benefits)Position OverviewA well-established manufacturing organization is seeking a hands-on Process Engineer to support daily plant operations and drive improvements in safety, quality, productivity, cost, and overall equipment performance.This individual will work closely with Operations, Maintenance, Engineering, Quality, and plant leadership to optimize manufacturing processes, reduce downtime and scrap, improve material utilization, troubleshoot production issues, and support equipment and capital improvement projects.The ideal candidate is a practical, data-driven engineer who enjoys spending time on the manufacturing floor and solving real-time production challenges.Key ResponsibilitiesProvide hands-on technical support to manufacturing operations and lead troubleshooting efforts for production and process-related issues.Analyze manufacturing performance, including scrap, downtime, production rates, yield, and material usage, to identify opportunities for improvement.Develop and maintain process documentation, operating procedures, work instructions, and training materials.Improve process capability and reduce variation to ensure consistent product quality and compliance with manufacturing standards.Lead initiatives focused on reducing:Scrap and wasteEquipment downtimeCycle timesMaterial usageUtility consumptionDirect labor requirementsUse data and structured problem-solving techniques to identify root causes and implement sustainable corrective actions.Apply continuous improvement methodologies including Lean Manufacturing, Six Sigma, 5S/6S, Kaizen, TPM, Value Stream Mapping, DOE, FMEA, and advanced root-cause analysis.Support the development and implementation of updated manufacturing standards following process improvements.Evaluate production layouts, work cells, and material flow to improve efficiency and support visual-management and 5S initiatives.Identify and implement new manufacturing equipment, automation, and technologies.Support capital equipment projects from initial concept through implementation, including:Equipment specificationsScope developmentRFQs and vendor evaluationThroughput and capability requirementsProcess parametersControls and data-acquisition requirementsInstallation and commissioningSafety reviewsEmployee trainingProduction ramp-upWork closely with equipment suppliers, contractors, Maintenance, Operations, and Engineering during equipment installations and process improvements.Participate in cost-reduction and productivity-improvement initiatives across the facility.Continuous Improvement & Problem SolvingThe Process Engineer will play a key role in developing and executing improvement projects involving:Process optimizationScrap reductionDowntime reductionYield improvementThroughput improvementMaterial optimizationEquipment reliabilityProcess capabilityAutomationLabor efficiencyManufacturing cost reductionCandidates should be comfortable analyzing manufacturing data, identifying trends, conducting experiments, and implementing corrective actions directly on the production floor.Safety ResponsibilitiesPromote a strong safety culture throughout the manufacturing operation.Participate in hazard identification, near-miss reporting, incident investigations, and corrective-action activities.Ensure engineering projects and process improvements incorporate appropriate safety considerations.Follow all company and applicable OSHA, environmental, and workplace safety requirements.Properly utilize required personal protective equipment while working in manufacturing areas.Support housekeeping, 5S, and safe-work practices throughout the facility.Cross-Functional CollaborationPartner closely with Production, Maintenance, Quality, Engineering, EHS, and plant leadership.Communicate technical findings, recommendations, and project status clearly to both hourly and salaried employees.Develop strong working relationships with operators and supervisors to drive sustainable process improvements.Provide technical training and coaching related to new processes, equipment, and operating procedures.QualificationsRequiredBachelor's degree in Mechanical Engineering, Electrical Engineering, Materials Engineering, Manufacturing Engineering, or a related engineering discipline.Approximately 3–10 years of manufacturing engineering, process engineering, or related plant experience.Experience working within a manufacturing or production environment.Strong troubleshooting and analytical problem-solving abilities.Experience analyzing manufacturing data and implementing process improvements.Strong written and verbal communication skills.Ability to work effectively across Engineering, Operations, Maintenance, Quality, and plant leadership.Hands-on approach with a willingness to spend significant time on the manufacturing floor.PreferredExperience in a high-volume or continuous manufacturing environment.Strong Process Engineering, Manufacturing Engineering, or Continuous Improvement background.Lean Manufacturing or Six Sigma experience.Six Sigma Green Belt or Black Belt certification.Experience with Design of Experiments (DOE).Experience with FMEA, root-cause analysis, Kaizen, TPM, 5S, and Value Stream Mapping.Understanding of automation, sensors, controls, and PLC-based manufacturing equipment.Experience supporting capital-equipment installation, commissioning, or production ramp-up.Background in plastics, extrusion, polymer processing, building products, or other continuous-process manufacturing is highly desirable.Work EnvironmentThis position works primarily onsite within an active manufacturing facility. The role includes a combination of office-based engineering work and significant time on the production floor.Employees may be exposed to normal manufacturing conditions including elevated noise levels, moving equipment, and production machinery. Appropriate PPE may include safety glasses, hearing protection, safety footwear, hard hats, and other equipment depending on the work area.Occasional travel may be required for vendor visits, equipment evaluations, training, or project support.