Airlite Plastics is a premier, privately held, family-owned manufacturer headquartered in Omaha, Nebraska. Our family style and personal culture is what makes Airlite an amazing place to grow and build a successful career. Airlite’s company values of unquestionable integrity and respect and appreciation for each other are at the core of our success! These values set a strong foundation to build on where we can ‘wow’ our customers with innovative products and sustainable solutions, and continuously improve our processes and efficiencies.
Our product lines include rigid plastic containers and lids for food packaging and cosmetics, dry powder scoops, plastic drink cups, shipping containers, industrial strength insulated concrete forms (ICF) and sustainable permeable paving systems. As pioneers in our industry, focused on sustainable solutions, we strive to provide our customers with top-notch service and quality, which aligns with our award-winning products.
How would you contribute?
This role is a contributing member of our Airlite - Pennsylvania team, located in Nazareth, PA. As a Process Engineer you are a key to continued growth and success of Airlite. The Process Engineer role supports the strategic priorities of the engineering department to ensure safe, efficient, high-quality production of extruded and injection molded plastic, and expanded polystyrene parts.
ESSENTIAL JOB DUTIES & RESPONSIBILITIES:
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Support the strategic priorities of the engineering department to ensure safe, efficient, high-quality production.
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Continuously evaluate existing processes and systems to identify opportunities for improvement. This may involve conducting process audits, analyzing performance metrics, and implementing corrective actions to optimize operations.
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Identify areas for process improvement and drive implementation and adoption to enhance efficiency, reduce costs, and increase productivity. This routinely involves analyzing data, conducting experiments, and implementing new technologies or methodologies.
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Develop and design efficient processes for manufacturing operations in plastic extrusion, injection molding, and foam molding. This includes, but is not limited to, conducting feasibility studies, creating process flow diagrams, developing standard processes, and training production teams to ensure that safety, quality, and efficiency expectations are met.
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Analyze data using Statistical Process Control (SPC) and Six Sigma tools to achieve continuous improvement goals plant-wide; considered to be a subject matter expert in each of these areas.
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Support, establish, and manage machine operating standards by developing, utilizing and continuously improving standard operating procedures for all processes.
- Maintain accurate documentation of processes, procedures, and changes. Generate reports and provide data-driven insights to stakeholders, management, and cross-functional teams.
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Collaborate with production teams to maximize machine performance and ensure that manufacturing changeovers are completed in accordance with established standards.
- Train and support the manufacturing teams on new processes, equipment, and technologies.
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Assist in troubleshooting process-related issues and implementing corrective actions.
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Assist and lead efforts in equipment troubleshooting, repair, installation, change-over, and PM as necessary.
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Consult with internal and external subject matter experts to resolve technical and process control issues.
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Report food safety concerns to leadership.
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Perform other duties as assigned.
Do you have what it takes? Airlite Plastics is a versatile employer; complacency is not one of our strengths! We work hard each day to ensure that equipment efficiency and customer satisfaction never leave our line of sight. Successful candidates for the role will possess the following:
Qualifications, Knowledge, Skills, and Abilities Required:
- Demonstrated experience in driving process improvement for plastic extrusion and injection molding.
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Proven track record driving process yield enhancement, cost reduction, and SPC systems.
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Experience with process development, optimization, and validation and design of experiments and statistics.
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Ability to learn new technologies and become a subject matter expert quickly.
- Expert knowledge of process improvement methodology.
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Hands-on approach and naturally inclined to be engaged with and present on the production floor.
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Proven track record driving process yield enhancement, cost reduction, and SPC systems.
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Capability to troubleshoot and solve complex problems utilizing critical thinking and decision-making skills.
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Superior organizational skills and the ability to assemble resources needed to orchestrate multiple projects/activities and accomplish goals.
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Model a collaborative leadership style with the ability to build partnerships and influence others into action.
- Excellent verbal and written communications skills and outstanding presentation and facilitation skills.
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Excellent interpersonal skills and a consultative approach; tactful in dealing with people at all levels.
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Ability to actively lead change initiatives.
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Strong sense of urgency, self-motivated and positive.
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Detail oriented, with the ability to multi-task in a fast-paced environment.
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Flexible and adaptable; able to work in ambiguous situations.
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Holds self and others to the highest ethical standards.
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Maintains the utmost level of confidentiality in dealing with sensitive information.
Education / Experience / Certifications:
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Bachelor of Science (BS) degree in a relevant engineering discipline from an ABET accredited institution.
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A minimum of five years’ relevant experience in the plastics industry, with extrusion and injection molding preferred.
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Experience in manufacturing operations, process validation, and design of experiments is required.
Supervisory Responsibilities:
This role does not have personnel supervisory responsibilities; however, this role includes working with cross-functional teams in a matrixed organization.
Physical Demands and Work Environment:
While performing the duties of this job, the employee is regularly required to sit; stand; walk; use hand dexterity to operate office equipment including computer keyboards, and common hand tools; reach with hands and arms; and talk and hear. The employee must occasionally lift and/or move up to 30 pounds. Specific vision abilities required by this job include close vision, distance vision, color vision, peripheral vision, depth perception, and ability to adjust focus.
While performing the duties of this job, the employee may be exposed to moving mechanical parts. The noise level in the office work environment is typically quiet; when visiting the production floor the noise level may be loud.
Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.
Our Core Values Drive Us!
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Do you conduct yourself with unquestionable integrity?
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Do you demonstrate respect and appreciation for those around you?
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Are you innovative and strive to challenge the status quo?
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Do you strive for continuous improvement and to deliver the “wow” factor?
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Do you care about environmentally sustainable solutions?
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Do you take meaning and pride in a job well done?
What’s in it for you? As a Full-Time employee, you will be eligible for the following benefits:
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Health, dental and vision insurance
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Company paid life insurance
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Company paid short term disability
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Generous 401k match
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Generous Time Off
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Annual company activities
