The posting
Process Engineer
Reports to:
Engineering Manager
Work Location:
RTP - Plant
FLSA Status:
Exempt
Position Summary
The Process Engineer is responsible for optimizing, improving, and sustaining manufacturing processes used in the production of copper powders and related metal powder products. This position focuses on process stability, product quality, production efficiency, safety, cost reduction, and continuous improvement initiatives. The Process Engineer works closely with operations, maintenance, quality, EHS, and leadership teams to develop and implement technical solutions that enhance plant performance, increase throughput, and support business objectives.
Essential Duties and Responsibilities
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Analyze and optimize copper powder manufacturing processes, including raw material handling, melting, atomization, reduction, classification, blending, screening, packaging, and material movement operations.
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Monitor process performance through data collection, statistical analysis, and process capability studies.
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Identify opportunities to improve productivity, yield, quality, energy efficiency, and overall equipment effectiveness (OEE).
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Lead root cause investigations related to process deviations, product quality issues, equipment performance concerns, and customer complaints.
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Develop and maintain process documentation, work instructions, standard operating procedures, and process flow diagrams.
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Support new product development and scale-up activities through process validation and production trials.
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Partner with maintenance and operations teams to troubleshoot process-related equipment issues and improve reliability.
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Implement Lean Manufacturing, Six Sigma, and continuous improvement methodologies throughout the facility.
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Conduct risk assessments and participate in Management of Change (MOC) activities related to process modifications.
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Evaluate and recommend equipment upgrades, automation opportunities, and capital improvement projects.
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Assist with plant commissioning, startup, and process qualification activities for new equipment and production lines.
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Support environmental, health, and safety initiatives by ensuring processes comply with regulatory and company requirements.
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Participate in cross-functional teams to achieve operational objectives and strategic initiatives.
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Prepare technical reports, presentations, and performance metrics for leadership review.
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Provide technical support and process training to operations personnel.
Supervisory Responsibilities
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No direct supervisory responsibilities.
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May provide technical leadership, coaching, and project direction to operators, technicians, contractors, and cross-functional team members.
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May lead project teams associated with process improvement and capital projects.
Qualifications
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Bachelor's degree in Chemical Engineering, Metallurgical Engineering, Materials Science Engineering, Mechanical Engineering, Industrial Engineering, or related technical field required.
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Minimum of 3-5 years of manufacturing engineering or process engineering experience.
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Experience in powder metals, metallurgy, chemical processing, metals manufacturing, mining, materials processing, or similar industrial manufacturing environments preferred.
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Experience with continuous improvement, process optimization, and statistical analysis techniques.
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Experience managing projects and implementing process improvements preferred.
Skills and Competencies
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Strong understanding of manufacturing process control and continuous improvement methodologies.
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Knowledge of metallurgical principles, material properties, and powder manufacturing processes preferred.
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Proficiency in root cause analysis tools including 5 Whys, Fishbone Diagrams, FMEA, and CAPA processes.
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Working knowledge of Lean Manufacturing and Six Sigma principles.
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Strong analytical and problem-solving skills with the ability to interpret complex process data.
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Ability to create and maintain technical documentation and engineering reports.
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Strong project management and organizational skills.
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Proficiency with Microsoft Office Suite and process analysis software.
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Excellent verbal and written communication skills.
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Ability to effectively collaborate with all levels of the organization.
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Results-oriented with a focus on safety, quality, reliability, and operational excellence.
Physical Requirements
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Ability to walk throughout manufacturing and warehouse areas for extended periods.
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Ability to ascend and descend ladders, stairs, and elevated platforms.
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Ability to occasionally lift and carry up to 25 pounds.
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Ability to wear required personal protective equipment, including safety glasses, steel-toed footwear, hearing protection, respiratory protection, and other equipment as required.
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Ability to conduct inspections in elevated, confined, hot, dusty, or industrial environments.
Work Environment
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Primarily located within a manufacturing facility producing copper powders and specialty metal powders.
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Exposure to industrial equipment, moving machinery, elevated temperatures, dust, noise, and vibration.
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Position requires regular interaction with production, maintenance, laboratory, and engineering personnel.
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Occasional travel may be required for training, project support, vendor visits, or professional development.
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Must adhere to all company safety policies, environmental regulations, and operational procedures.
