Thermoplastic Process Engineer




United States, Morgan Hill, CA

Level of experience

Mid Level

Contract type


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Job Description


The Process Engineer will take full technical ownership for at least two full production process lines, as part of a larger thermoplastics operational team that is preparing for substantial growth. The Engineer will be responsible for complete process control and technical oversight of a continuous production process, to ensure maximum up-time, with highest efficiency and excellent quality. Additionally, the engineer will provide production support, new product development and production integration.

Primary Objectives & Responsibilities of the Position

This is a hands-on process engineering role, and will require ingenuity, flexibility and problem-solving capabilities. A primary objective is to maintain and improve the consistency of the production processes, recommend updates to process control, monitoring and pioneer equipment/technology upgrades.

The process engineer will become intimate with the methodology and techniques to produce continuous reinforced advanced thermoplastic composite materials. The Engineer will also:

  • Recognize and troubleshoot problems associated with all aspects of unidirectional tape manufacturing processes and associated Quality Assurance processes.
  • Prioritize and optimize all aspects of environmental health and safety with regards to the tooling, equipment, ergonomic practices and overall production processes.
  • Develop clear, logical standard work processes in partnership with the production team, focused on safety, quality and cost control.
  • Create concise, accurate manufacturing configurations, bills of materials, routers, work instructions. These will be compliant to the QMS system, either ISO 9001 and/or AS9100.
  • Plan and executes capital projects and process improvement activities as business priorities demand.
  • Support establishing and measuring process performance standards associated with quality, process control and total production throughput. Using SPC methods and control plans, will continuously optimize process capability using a data-driven approach.
  • Supports investigations and resolves operational non-conformances and customer or supplier related issues.
  • Participate in customer site audits/qualifications and visits at TenCate; will represent the company in a professional manner.
  • Successfully manage multiple projects.
  • Assist as needed with training production associates on manufacturing processes.
  • Be flexible in working hours if/when production needs dictate. Travel occasionally if necessary to support customer/supplier/internal projects and engineering activities.

Qualifications & Education

  • Minimum BS Degree (Mechanical, Manufacturing Aerospace, or Chemical) Engineering
  • Minimum 3 years of experience in a manufacturing or industrial setting.
  • Practical application and hands-on experience with improving process capability strongly desired. Strong preference for candidates skilled in six sigma methodologies / SPC and lean manufacturing tools.
  • Working experience of quality management systems essential; AS9100 experience a plus.
  • Experience & technical knowledge of composite and plastic materials preferred. Die design and extrusion process knowledge would be ideal.
  • Experience with polymer extrusion processes desirable, in-particular PP, HDPE, PA6, PET, PC, ABS, PC/ABS materials.
  • Experience with production ramp-up and/or new product/process development preferred.
  • Knowledge of business ERP systems is preferred (Microsoft Dynamic AX® or similar).
  • Continuous improvement bias, willing to challenge, and continually push process improvement. Strong problem-solving mindset, aggressively seeking root cause corrective actions.
  • Strong analytical skills, able to derive useful information from various data sources to enable logical, data-driven decision making.
  • Excellent interpersonal, communication and organizational skills and the ability to work effectively in a cross-functional team, with all levels of the company.
  • Energetic and takes initiative, accepts accountability and displays decisiveness in initiating actions and managing to completion.

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