Process Engineering Manager

Toray Advanced Composites (TAC) is a leading supplier of advanced composite materials for the aerospace, sporting goods, motorsport, 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 composites 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 aircraft, 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 PEEK, PPS, PEI as well as a full line of performance thermoplastics including Nylon, PET, PC/ABS, HDPE, and PP.

SUMMARY OF FUNCTIONS:

The Process Engineer Manager will be responsible for a team of process engineers to ensure the methods, development, implementation, equipment designed for the manufacturing processes. This role will lead a team of highly qualified engineers to ensure quality standards are consistent with established standards, customer specifications, and production goals. Additionally, this person will provide leadership, direction, mentorship, and supervision to their team. The Process Engineer Manager will be responsible for the technical ownership of training and developing processes engineers. The manager will be responsible for the complete process control and technical oversight of a continuous production process to ensure maximum up-time, with highest efficiency, excellent quality, and provide mentorship and technical guidance to other process engineers. The Process Engineer Manager will lead multiple departmental efforts with new product development and production integration. The primary objective of the department is to improve and contribute to the consistency of the production processes, recommend and execute upgrades to process control, and take leadership in production/equipment upgrades. This role will look for continuous production advancement materials that meet or exceed the safety regulation and our customers’ expectations. The manager is accountable for all process engineers and is responsible for answering/brainstorming technical questions and general guidance.

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

MAJOR DUTIES AND REQUIREMENTS:

• Responsible for managing a team of process engineers on 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.
• Support internal audit schedules and ensure that assigned Corrective Action Requests are completed by agreed upon due dates. 
• Identify gaps by analyzing SOPs and their effectiveness for the business processes.
• Develop and implement safe, optimal, cost-effective manufacturing processes, methods, and equipment platforms.
• Respond to customer requirements and / or complaints in a timely fashion.
• Perform research, design, and development of manufacturing processes, including production workflow, raw material specifications, and equipment specifications.
• Recommend and implement continuous improvements to manufacturing processes, methods, and controls.
• Design, develop, test, and/or outsource various processes, machinery, and equipment for recommended manufacturing methods.
• Develop manufacturing Configurations, Bills of Materials, Routers, Work Instructions, and Control Plans using manufacturing engineering best practices.
• Perform product/process analysis and implement continuous improvement initiatives for cost reduction, scrap reduction, yield improvements and increased overall equipment efficiency.
• Conduct PFMEAs (process failure mode and effect analysis) or root cause analysis on manufacturing processes, methods, equipment, products, and controls.
• Represent process engineering on cross-functional teams.
• Participate in concurrent engineering design reviews.
• Support the conversion of small-scale processes into commercially viable large-scale operations.
• Coordinate manufacturing launch for new or revised products, processes, and equipment.
• Create Capital Expenditure requests and ensure the project is executed on time and within budget. 
• Mentor and train process engineers in the applications of data driven problem solving.
• Ensure safety minded employees and implement safety minded SOPs within the organization.
• Collaborate with all related functions including Manufacturing, Maintenance, Process Technology, R&D, Quality Assurance and Inventory to achieve the company's objectives.
• Must be able to support multiple projects.
• Assist in responsibility for the safety and environmental issues associated with the manufacturing processes and equipment.
• Support process engineering and operation department managers in his/her functional activities, and performs other duties as assigned.
• Must be 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 discipline
• More than 5 years of experience working in composite materials, aerospace manufacturing industry preferred.
• Minimum of 1 year of leadership experience, preferably managing teams of engineers and/or technicians.
• Advanced leadership training is a plus.
• Knowledge of thermoset and thermoplastic resin systems is highly preferred.
• In depth knowledge of statistical analysis, process control, project management, RCCA and FMEA
• Lean and Six Sigma training, green belt required, black belt preferred.
• Root Cause, PFMEA, Statistics & SQC/SPC
• Knowledgeable and in depth understanding of business ERP system (Microsoft Dynamic AX 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)

Salary range:  $110,000 - $150,000/year

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.