Directs and coordinates department activities to continuously improve OEE (Overall Equipment Efficiency) by improving Availability, Rates and Quality while performing the following duties:
Essential Duties and Tasks
Knows and follows all safety policies and procedures. Holds all crews accountable for working safely and ensures compliance with safety policies and procedures. Assists EHS Manager in investigations of incidents and near misses and conducts Root Cause Analysis (RCAs) to determine corrective actions. Develops new SOPs if necessary to support safety initiatives and trains personnel against new SOP.
Commitment, awareness and involvement pertaining to ISO (policy, standards, procedures, etc.) and food safety practices (GMPs, procedures, etc.) are requirements of all employees.
Responsible for identifying, assessing, prioritizing, testing, and implementing process improvement projects that support and sustain departmental and plant goals.
Onsite and offsite troubleshooting of process issues related to equipment and materials, working closely with production personnel, product development engineers, maintenance, management, and on occasion customers.
Implements solutions to the root cause of problems, and follows up with affected personnel regarding any process, product, or equipment changes.
Uses a combination of practical knowledge & experience, engineering principles, facts and data, and systematic troubleshooting techniques to completely identify and eliminate process issues in the manufacturing environment.
Implements and validates conformance to IQ/OQ/PQ program.
Performs independent quality validation checks. Conducts daily audits of run conditions, samples, QC data. Updates and maintains files with data, and report information through spreadsheets and graphs.
Implements applicable Statistical Process Control tracking and reviews data on a daily basis. Brings areas of concern to appropriate manufacturing managers.
Primary driver for RCA development, resolution, implementation and continued conformance when applicable. Investigates internal and external complaints by doing root cause analysis and applying corrective actions.
Works closely with Product Development Engineer to formulate, review, and administer Extrusion and Rewinding trials. Develops trial packets and run conditions, documents trial results, maintains trial folders, and works with PD Engineers to improve product performance and profitability. Primary focus in development effort is assuring newly developed products meet VOC, are commercially ready, and can be produced efficiently at acceptable quality levels.
Updates Standard Operating Procedures, and conducts training accordingly.
Contributes to planning of production operations by establishing priorities and sequences for manufacturing products.
Reviews QC specs daily to ensure accuracy; makes corrections as needed through Data Control personnel.
Works closely with Continuous Improvement personnel on process improvement initiatives. Contributes machine knowledge to the process.
Demonstrates appropriate attitude in all dealings with co workers, customers, and suppliers.
Use of CAD program for capital projects and for Machinery Tooling Designs.
Lead multiple cost savings Continuous Improvement Projects
Lead DOE Matrices for Process Improvement
Other duties as assigned.
Qualifications, Education and Experience
Chemical, Mechanical or Industrial Engineering degree with 5+ years of plastics, paper processing, and/or flexible packaging experience or equivalent combination of education and experience.
Working knowledge and experience implementing SPC, IQ/OQ/PQ, DOE. Prefer experience in Six Sigma and Lean Manufacturing training with Black Belt certification.
Knowledge of plastics extrusion, web handling, web winding, and associated process equipment strongly desired. Strong systematic troubleshooting and communication skills a must.
Self-motivated and energetic with ability to clearly communicate with various levels of the organization from Machine Operators to upper Management.