Process Quality Engineer in Nesquehoning, Pennsylvania at Westchester Plastics LLC

The Process Quality Engineer is responsible for ensuring consistent product quality, optimizing manufacturing processes, and driving continuous improvement initiatives throughout the plastics compounding operation. This position works closely with Production, Quality Control, Maintenance, Sales, and Customers to improve process capability, reduce waste, resolve quality issues, and maintain compliance with customer specifications and industry standards.

Process Engineering

• Monitor and optimize plastics compounding and extrusion processes to improve product consistency and manufacturing efficiency.
• Analyze process data and identify opportunities to reduce variability, scrap, downtime, and cycle times.
• Develop and maintain standard operating procedures (SOPs), process parameters, and work instructions.
• Support new product launches, material trials, and production scale-up activities.
• Validate process changes and ensure successful implementation.

Quality Management

• Investigate customer complaints and internal quality issues using structured root cause analysis techniques.
• Implement corrective and preventive actions (CAPA) and verify effectiveness.
• Monitor key quality metrics including scrap, rework, yield, and customer returns.
• Maintain process documentation, control plans, inspection procedures, and quality records.
• Ensure compliance with ISO quality management systems and customer-specific requirements.
• Analyze production and quality data using SPC and statistical tools.
• Generate reports on process capability, quality performance, and continuous improvement metrics.
• Recommend process improvements based on data trends.

Continuous Improvement

• Lead Lean Manufacturing and Six Sigma improvement projects.
• Reduce process variation through statistical analysis and process capability studies.
• Identify opportunities to improve Overall Equipment Effectiveness (OEE).
• Support cost reduction initiatives through process optimization and waste elimination.

Production Support

• Provide technical support to production personnel during troubleshooting activities.
• Train operators on process controls, quality standards, and best manufacturing practices.
• Assist in developing standardized process settings for various compounds and resin systems.
• Collaborate with Maintenance to improve equipment reliability and preventive maintenance programs.

Qualifications

• Bachelor’s degree in chemical engineering, plastics engineering, mechanical engineering, industrial engineering, or a related technical field.
• 1–5 years of manufacturing engineering or quality engineering experience, preferably in plastics compounding, extrusion, or polymer processing.
• Experience with color concentrates, engineered resins, recycled materials, or custom compounds is preferred.

Required Skills

• Strong understanding of plastics processing, compounding operations, and/or manufacturing.
• Knowledge of polymer properties and material behavior.
• Process capability analysis.
• Familiarity with Lean Manufacturing methodologies.
• Root cause analysis and structured problem-solving skills.
• Familiarity with ISO 9001:2015 quality systems.
• Strong communication and cross-functional leadership abilities.
• Proficiency with Microsoft Excel and ERP systems. Technology savvy.
• Ability to interpret customer specifications and technical documentation.

Physical Requirements

• Ability to work in a manufacturing environment with exposure to heat, cold, noise, and moving equipment.
• Ability to lift up to 50 pounds occasionally.
• Ability to stand and walk throughout the production facility.

Salary Range

• 65K to 75K