Process Engineer

Description

Due to growth and internal development we are now looking to hire additional resources for our Quality Assurance Team! 

Summary:

Member of the Quality Assurance Team. Provide   process engineering support and education to operators and supervisors in the Bar Mill, Cast Shop, and Rolling Mill. Provide limited support to Architectural Services. Monitor, control and make recommendations for improvements to various phases of manufacturing processes and equipment. Specify processing steps and processing parameters to manufacture Rolled Products to meet customer product requirements. Leads projects focused on continuous improvement of production processes.

Duties and Responsibilities:

• Investigate   production process needs. 
• Coordinate and   implement projects and action plans.
• Review customer   requirements and specifications against manufacturing capabilities.
• Assure process   used to manufacture product meets or exceed customer expectations.
• Evaluate Customer Inquiries for manufacturability and advise Customer Support and   Marketing of unusual requirements that would affect lead-time and production cost/efficiency.
• Review and make recommendation for changes to Revere ASTM/CDA representative on various documentation and standards as requested.
• Determine   alternative processing options to best utilize available capacity on mill   machinery.
• Utilize Process   Engineering Methods to Create and Modify:
• Product Masters
• Process Masters
• Customer   (Testing) Element Files
• Packaging Instructions
• New Material Request Documentation for new and experimental materials used in processing   and/or testing.
• Analyze and respond to customer complaints   and corrective action requests:
• Reports Root Cause and Corrective Actions on Customer Complaints
• Refer off-quality products to affected Customers through Customer Support
• Visit Customers, outside Processors and MRO Vendors plants as necessary.
• Apply Technical applications of Process Engineering:
• Perform   Capability and Control Statistical Studies internally and externally.
• Complete and   maintain various APQP demands, including PPAP’s, Capability Studies, Part   Warrants, Gaging R&R, Process Flow Diagrams, PFMEA/FMEA’s, etc. 
• Use various diagnostic equipment and tools to monitor various Process Parameters. 
• Perform simple laboratory testing such as pH, Hardness, Conductivity. 
• Conduct process walks to observe material, processes, and operators. 
• Create disposition of Non-compliant Product.
• Lead /participate in Mill Tours to visiting Customers, Vendors, and Community Members.
• Attend Architectural trade shows.
• Attend periodic meetings with Operations, Quality, and Sales & Marketing.
• Attends Weekly Reliability and Maintenance Planning Meetings and Backlog Meetings.
• Completes and maintains various APQP demands, including   PPAP’s, Capability Studies, Part Warrants, Gaging R&R, Process Flow Diagrams, PFMEA/FMEA’s, etc. 
• Creates and Modifies Job Instructions, Quality Assurance Plans, JIB’s, OJT’s etc. within Revere Document Control System.
• Initiates New Material Request Documentation for new and experimental materials used in processing and/or testing.
• Participates in Audits by Independent 3rd Parties and Customers.
• Perform   Internal Audits, write audit findings, lead discussions at Audit Closing Meetings.
• Performs metallographic investigations on various samples to help determine root cause of defects when necessary.
• Reports Key Process and Product Metrics to various levels of the organization.
• Uses various diagnostic equipment and tools to monitor different Process Parameters. These include; dimensional gauging tools, thermometric devices, process data recording devices, hand-held tools, hand-held Profilometers, etc.

Requirements

Qualifications:

Minimum:

• 1 – 3 years’ experience as a Process Engineer in the production of Primary Metals (Steel, Aluminum, Copper) with knowledge and   understanding of the relationship between process inputs and outputs.

Preferred:

• 3 – 5 years of experience in the manufacture and quality management of primary metals (Copper, Steel, Aluminum), Mechanical and Physical material testing of metals.
• Experience in Problem Solving Methodology, Containment and Corrective Action Processes, APQP techniques.
• Thorough knowledge of Statistical Process Control techniques.

Special Demands:

• Lifting/Handling various product samples that may have sharp edges or burrs.
•  Exposure to Corrosive and volatile process Chemicals.
• Extremities of Heat/Cold mill environments.
• Possible dusty/smoky environments.
• Loud noise environments.
• Walking distances up to ¼ mile between various locations within the mill.
• Climbing/Descending Stairs and Ladders within the mill and offices.
• Exposure to mobile equipment and overhead cranes.
• Standing for long periods.
• Possible slippery floors and walkways.
• Outdoor work is possible.
• Reduced lighting environments are possible.
• Proximity to moving machinery.
• Occasional overnight travel.

Education / Training:

Minimum:

• Bachelor degree in a Physical Science (Physics, Chemistry) or Mechanical Engineering, Mechanical Technology, or Chemical Engineering. 
• Knowledge of Statistical Techniques is a plus. 
• Proficiency in Microsoft Office products.

Preferred:

• Bachelor Degree in Material Science, Extractive Metallurgy, or Refractory Engineering. Six Sigma Certification, and experience in APQP methodology.
• Graduate studies or Master’s degree.