Manufacturing Process Engineer

Direct and coordinate the activities of the coating department by performing the following duties:

• ◆Serve as the subject matter expert for the end-to-end PTFE coating process, including web handling, tension control, coating application, drying, and cure profiles.
• ◆Define, document, and maintain optimal process parameters (line speed, oven zone temperatures, coating add-on/weight, and tension) to ensure consistent, repeatable output across products, shifts, and equipment.
• ◆Design and develop coating processes for new products, applications, and substrates, translating customer and product

into robust, manufacturable process specifications.

• ✓Establish and maintain process control plans, capability studies, and standard operating conditions for the coating line.
• ✓Apply engineering concepts, techniques, analysis, and decision tools throughout each improvement process initiative.
• ✓Drive continuous improvement initiatives that reduce process variation, scrap, and rework while improving yield, throughput, and first-pass quality.
• ✓Apply Lean and Six Sigma methodologies (e.g., DOE, SPC) to standardize processes and systematically eliminate sources of variability.
• ✓Research and roll out new methods, materials, and equipment designed to improve processes and reduce costs, including creating ROI for proposed solutions.
• ✓Identify areas for cost reduction and implement process efficiencies.
• ✓Serve as the lead technical resource to deep-dive, diagnose, and resolve coating quality issues such as coating-weight variation, marking, wrinkling, adhesion, and surface defects.
• ✓Utilize root cause analysis tools such as 8D, 5-Why, and fishbone to analyze, understand, and correct issues, driving corrective and preventive actions to closure.
• ✓Partner with Quality Assurance to analyze nonconformances, customer complaints, and RMAs, translating findings into permanent process improvements.
• ✓Develop and lead project teams for research and development of new processes and equipment for existing and new products.
• ✓Develop and adhere to project budgets and timelines, delivering large projects on-time and within budget.
• ✓Partner with outside sources, including equipment vendors and contractors, to deliver projects on-time and within budget.
• ✓Effectively manage time and strategically prioritize projects in line with AFC’s needs.
• ✓Train, coach, and develop coating operators on standardized methods, process controls, and best practices to build technical capability and consistency across the team.
• ✓Create documentation to support and implement improved processes and cost reduction (e.g., SOPs, work instructions, CAD designs).
• ✓Mentoring and development of in-direct reports.
• ✓Work in conjunction with other departments’ heads to develop optimal process designs and efficient utilization of resources.
• ✓Follow all safety and quality guidelines for maximum throughput in keeping with corporate policies and goals.
• ✓Ensure the daily safety of all direct reports by promoting and enforcing a safe working environment.
• ✓Monitor performance metrics and implement continuous improvement initiatives.
• ✓Promotes a positive team environment and rewards and recognizes individual efforts.
• ✓Must be a leader embracing and modeling AFC’s Core Values.
• ✓Perform other duties as assigned.