The Senior Manufacturing Process Engineer is a leading member within the Process Engineering organization. This individual plays a vital role in the development of new manufacturing processes, material flow, and standard operating procedures. The Sr. Process Engineer sets up and ensures satisfactory operation of new equipment, then teaches others on its proper use and maintenance. The Sr. P. E. leads the implementation of Lean-Sigma methodologies, researching leading edge processes and best practices, supporting cross-functional projects focused on achieving the highest possible levels of product quality and operational excellence. Additionally, this individual will mentor junior engineers and provide technical leadership to the operations team.
Plans new manufacturing processes and justifies new equipment to meet projected production requirements, ensuring production lines operate at optimum efficiency.
Commissions new equipment and processes.
Leads complex cross functional continuous improvement projects.
Mentors junior engineers and operational staff.
Core Duties and Responsibilities
Ensures compliance to all Regulatory (Local, Federal), Corporate, and Plant standards.
Develops and maintains a detailed understanding of Plug Power products and related manufacturing objectives and engineering constraints.
Develops and improves manufacturing processes and material flow by studying product requirements; researching, designing, modifying, and testing manufacturing methods and equipment; soliciting feedback from production technicians; and conferring with equipment vendors.
Leads the implementing of process improvement projects, Kaizen and training events using Lean-Sigma tools, including safety, ergonomics, 5S, Kanbans, statistical process control, standard work, and visual controls.
Monitors process improvement progress and leads team problem solving projects including root cause analysis, containment, corrective, and preventative action implementation.
Develops, maintains, and communicates manufacturing process performance metrics (KPI’s).
Coordinates with production and warehouse staff to support manufacturing process and material flow needs, alleviating production constraints, improving product quality and overall process efficiency.
Utilizes and improves business process systems (quality & test data bases, ERP system, project management software, etc.) to support continuous improvement efforts.
Develops and maintains standard operating procedures (SOP’s).
Coordinates with New Product Introduction and Engineering teams to improve design for manufacturability, reliability, and serviceability.
Manages cross-functional coordination to develop and maintain a comprehensive equipment management process, in-house fixture and tooling requirements, predictive & preventative maintenance requirements to increase our overall equipment effectiveness (OEE), and fulfillment of the quality measurement system specifications.
Supports the quality organization to ensure thorough and timely dispositions of non-conforming material in order to maintain continuity of production and containment of problems before they reach the customer.
Contributes to team Operational Excellence efforts by accomplishing related results as needed.
Represents Plug Power in a professional manner at all times.
Perform all other duties as assigned.
BS degree in Engineering (Mechanical, Electrical, Industrial, etc.), MS preferred
Minimum of seven (7) plus years of broad range of manufacturing experiences; oriented towards high speed, mass production systems
Lean Sigma green belt/black belt preferred
Proficient with solid modeling engineering systems (CREO – preferred)
Proficient in Geometric Dimensioning & Tolerancing (GD&T)
Familiar with computer-controlled machine tools and has had exposure to high-volume automated production equipment.
Proficient with Microsoft Office software
Dynamic interpersonal skills and the ability to translate complex methodologies to diverse audiences and stakeholders
Uncompromising dedication to product quality
Demonstrated analytical abilities with strong attention to detail
Ability to manage multiple complex projects and multi-task effectively
Proven track record of driving continuous improvement projects
Ability to work independently and as part of a team.
Ability to role model high standards of professionalism
Ability to mentor junior staff members
Must be driven and self-motivated