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Open nowPosted 9 hours ago

Senior Process Improvement Engineer - 1481

Workable (global search)107,801 open roles

Where
Dalton, GA, United States
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Your applicationOpen nowSenior Process Improvement Engineer - 1481Workable (global search) · Dalton, GA, United States

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8.0% of postings close within 7 days. Measured by our own scanner across the market. Workable (global search) postings stay open a median of 2 days.

Share of postings closed within
  1. 1.6%1 day
  2. 3.5%3 days
  3. 8.0%7 days
  4. 14.9%14 days
  5. 34.0%30 days
This job: posted 9 hours ago

Workable (global search) median: 2 days open

The posting

We are seeking an experienced Process Improvement Engineer with a strong background in carded needle-punch nonwoven manufacturing and fiber processing. This role will focus on improving the performance, consistency, efficiency, and quality of carded needle-punch nonwoven manufacturing processes. The successful candidate should understand how fiber characteristics and processing conditions affect carding, needle-punching and final nonwoven product properties. This is a hands-on manufacturing position requiring significant interaction with production equipment, operators, technicians, and engineering teams.

Key Responsibilities

  • Lead process improvement initiatives for carded needle-punch nonwoven manufacturing processes.
  • Optimize processes from fiber preparation and blending through carding, web formation, crosslapping, needle punching, and finishing.
  • Troubleshoot issues related to fiber opening, blending, fiber distribution, web uniformity, basis weight, thickness, density, and product consistency.
  • Optimize carding and web-forming conditions to achieve consistent fiber distribution, orientation, web weight, and uniformity.
  • Optimize needle-punch parameters including needle density, penetration depth, punch frequency, stroke, and line speed.
  • Evaluate the impact of fiber type, fiber length, denier, crimp, finish, blend ratios, and recycled content on manufacturing performance.
  • Conduct plant trials and process experiments involving new fibers, fiber blends, equipment settings, and process conditions.
  • Identify and eliminate root causes of scrap, defects, downtime, rework, and process variation.
  • Analyze manufacturing data to identify opportunities to improve throughput, yield, quality, and material utilization.
  • Establish and maintain appropriate process windows, operating standards, and process controls.
  • Use structured problem-solving methodologies including Root Cause Analysis, 5-Why, Fishbone, SPC, DOE, Lean, and Six Sigma tools.
  • Work with Maintenance and Engineering on equipment modifications and improvements.
  • Support new product development and commercialization by establishing repeatable manufacturing processes.
  • Develop and maintain SOPs, work instructions, process specifications, and control plans.
  • Train and support production personnel on optimized process conditions and standard operating procedures.
  • Track and quantify process improvement results, including cost savings, scrap reduction, productivity, yield, and capacity improvements.

Requirements

  • Bachelor's degree in Textile Engineering, Chemical Engineering, Mechanical Engineering, Materials Science, Manufacturing Engineering, or a related technical field.
  • 5+ years of experience in process improvement, process engineering, or manufacturing engineering.
  • Strong hands-on experience in nonwoven manufacturing and fiber processing.
  • Direct experience with carded needle-punch nonwoven processes.
  • Strong understanding of fiber processing, carding and needle punching.
  • Experience working with synthetic fibers and fiber blends, such as polyester/PET, polypropylene, or recycled fibers.
  • Experience troubleshooting manufacturing problems directly on the production floor.
  • Demonstrated experience improving manufacturing throughput, yield, quality, process capability, and material utilization.
  • Strong analytical and problem-solving skills with the ability to use manufacturing data to identify root causes and implement solutions.
  • Experience with Lean Manufacturing, Six Sigma, SPC, DOE, and root-cause analysis.
  • Strong communication and collaboration skills. Ability to work effectively with Production, Operations, Maintenance, Quality, R&D, and Engineering teams.
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