Sr. Process Development Engineer

Position Summary

Lead higher level engineering efforts to develop, and improve products, manufacturing processes, equipment and systems by defining specifications, materials and manufacturing procedures. Lead the identification and development of next generation processes related to plastics processing. Lead inputs to process design, develop and identify new manufacturing methods and design. Conduct scientific based testing to identify best practices and optimize process parameters to establish quality and dimensional stability of manufactured components while developing a robust validation package for the process.
 

Principal Responsibilities

1.    Make high level technical presentations to SBU leadership and executive management to convey project status and technical feasibility of projects related to plastics processing.
2.    Lead project team members or direct reports to meet multiple project objectives, milestones, and target dates.
3.    Interface with vendors to obtain quotations, purchase components, purchase equipment and debug problems in support of process development.
4.    Coordinate or participate as technical lead for manufacturing transfer of new products, including manufacturing trials, or existing products.
5.    Engineering lead for all aspects of process development including the design, prototyping, testing (verification), process characterization, process development history documentation, and design transfer into manufacturing with a robust validation package.
6.    Provide guidance, input and support to the redesign of existing processes to improve quality, utilize automated production techniques, optimize process capabilities, and produce better products in a more cost-effective manner.
7.    Independently plan and technically lead multiple projects utilizing project plans and schedules to track and communicate developments from prototype design through pilot production. Formulate decisions to facilitate project advancement independent of supervisor.
8.    Independently interface with product development and manufacturing to understand product requirements and establish design criteria for developing manufacturing processes.
9.    Conduct DOEs and use computer aided engineering tools such as SolidWorks to create and solidify product, tooling and manufacturing specifications.
10.    Identify and create new process concepts. Design and validate processes and components using engineering principles and adhering to the design control process as appropriate.
11.    Lead, conduct and/or participate in design and technical phase reviews.
 

Principal Responsibilities

12.    Monitor project progress by completing and distributing project reports, priority lists, time sheet and conducting design reviews.
13.    When appropriate, investigate or direct the investigation of product complaints to determine cause and implement corrective action.
14.    Provide training and documentation to production to ensure a smooth design transfer.
15.    Support, maintain and upgrade production, production processes, and assembly. Lead the identification, development and introductions of new processes and control methods into manufacturing as well as to create best practices in product development.
16.    Develop robust and capable processes ("Scientific Molding" Philosophies) for new and existing manufacturing products. Document, validate and determine standards for them.
17.    Prepares or reviews documentation with a high degree of accuracy, completeness, and effectiveness using engineering tools and templates where available (i.e. validation documents, specifications, manufacturing procedures, EDOs, and technical reports or analysis summaries).
18.    Applies and leads DMAIC- Six Sigma approaches to solve issues and reduce variation in all manufacturing and business processes.
19.    Consult with Teleflex and non-Teleflex engineers, technicians, drafts people, and manufacturing personnel regarding machine design, process/product design tooling/fixturing and production problems.
20.    Mentor technical personnel in the use of current best practices and advanced initiatives.
21.    Visit other Teleflex facilities as required to resolve manufacturing problems.
22.    Perform as the recognized subject matter expert for plastics processing through direction and consultation of other employees seeking related knowledge.
23.    Provide Technical support all manufacturing transfer of plastics processing operations across global operations.
24.    Adhere to and ensure the compliance of Teleflex's Code of Ethics all Company policies, rules, procedures and housekeeping standards.
 

Education / Experience Requirements

•    BS in Engineering, or equivalent, MS Degree preferred (Mechanical and/or Plastics Engineering)
•    7 years’ experience in process support and development; minimum of 3 years of previous experience in related field (e.g. medical device manufacturing & assembly, plastic injection molding, plastic extrusion, plastics, automation).
•    Must have medical device manufacturing and experience including transferring products from design to manufacturing.
•    Must have demonstrated ability and experience to balance and multi-task multiple engineering projects and programs in support of internal customers.
•    Expert understanding of polymer materials properties and the practical application of these principles in establishing robust manufacturing processes, troubleshooting, and consulting with R&D on material selection.
•    Must have working knowledge of Microsoft Office, Minitab, SolidWorks.
•    Must be able to apply engineering concepts, original thinking, cause and effect, and ingenuity to solve problems.
•    Must be skilled statistical practitioner and apply statistical analysis to determine process capabilities, compare populations via hypothesis testing, utilize process control charting, and use the output of these analysis to improve operations. Six Sigma certification is highly desirable.
•    Knowledge and experience in designing and performing Design of Experiments (DOE) desirable.
•    Able to travel domestically and internationally (up to 25%)
 

Specialized Skills / Other Requirements

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