Plastics Process Engineer

About the Company

Dörken Systems Inc. is a member of the DÖRKENGroup of companies. Dörken is a family-owned business that serves customers worldwide with premium products and services in multiple industries. Exciting challenges, professional development opportunities, attractive benefits and strong innovative manufacturing partnerships define Dörken as an employer.

As a family business for over 130 years, Dörken is built on strong values and relationships. Our core values include trust, humanity, innovation, sustainability, diversity, reliability and loyalty. These values are central to our daily interactions and form the basis of our long-term success.

Scope:

The Process Engineer is responsible for all technical aspects of the production processes at Dörken’s 24/7 operation in Beamsville, ON.

Role:
The Process Engineer’s role is to provide technical expertise with a goal of improving efficiency, reducing scrap and reducing costs through standardization and continuous improvement for all production machines and processes. This includes but is not limited to technical responsibility for all aspects of manufacturing of dimple sheets, flat sheets including extrusion, winding, packaging, slitting

Core areas of responsibility:

Safety:

· Responsible for improving production process efficiency and scrap in the following priority order:

1) Safety

2) Quality

3) Productivity

· The focus of all work ensures that policies and procedures regarding workplace safety, environmental protection and optimal use of resources are strictly adhered to at all times

· Ensures proper use of personal protective equipment (PPE) and appropriate tools at all times

· The Process Engineer actively contributes to risk assessments for production equipment, proposes measures and supports with the implementation of such measures to eliminate or minimize risks

Professional Competence:

Process Engineering / Productivity

Responsible for improving production productivity, process efficiency, scrap rates and costs by:

· Leads standardization of production processes and product changeovers

· Leads and updates / documents SOPs for processes, changeovers, etc.

· Leads and updates / documents optimal process parameters in Setup Sheets

/ Recipes

· Collaborates with cross-functional teams and other supporting departments from

Dörken Germany, equipment suppliers, etc.

· Leads, develops, updates / documents Troubleshooting Guides

· Leads, develops, updates / documents PFMEA (Process Failure Mode and

Effects Analysis)

· Provides technical resources and technical training to all plant departments,

including Production, Maintenance, Project, etc.

· Leads Continuous Improvements through

o incremental improvement projects (Kaizen)

o major improvement / capital projects

Key Performance Indicators (KPIs)

· Provides detailed analysis of KPIs related to productivity, including but not limited to OEE (Overall Equipment Effectiveness)

• Availability
• Efficiency (line speed, cycle times)
• Scrap rates

· Monitors and analyzes process performance metrics, such as line speeds, cycle time, yield and scrap rate, and develops strategies to meet or exceed targets

· Provides technical, process and machine improvement suggestions and follows up on effectiveness and results

Continuous Improvement

· Leads monitoring and analyzing of process data, identifying trends and proposing solutions for process improvement continuously

· Leads identification and implementation of process improvements to reduce costs, minimize waste and increase efficiency

· Continuous improvement proposals are made to the Director of Operations and are to be checked regarding suitability and financial effect

· Supports implementation of capital projects for equipment as related to productivity and technical improvements

Production Procedures

· Defines production procedures in collaboration with Quality Manager, Production Managers, and other supporting departments (e.g., Dörken Germany, equipment suppliers, etc.)

Deviation during production

· In case of deviations and problems occurring during production shifts, the Process Engineer provides necessary support in identifying the problem and its root cause, and in determining actions towards effective solutions

Quality

· Participates in cross-functional teams to drive root cause analysis, corrective actions and preventive measures.

· Specifications and targets regarding quality are to be observed at all times. This applies to both work quality and product quality. The Process Engineer will support the Plant departments regarding improvements in quality as it relates to processing.

· Collaborates with Quality Manager on statistical process capability analysis for determining stable processes.

· Identifies and implements process control measures, including statistical process control (SPC) techniques, to ensure consistent quality and reduce process variation.

· Internal and external quality audits are to be supported. Actions towards quality improvements as related to Process Engineering responsibilities are to be determined and implemented.

· Leads the process for controlled / documented engineering changes.

New Product / Process Development

· Leads in establishing standard processing methods and machine process parameters for new products/machines

· Collaborates with Product Management, Production Management and Quality Management on defining specifications for finished products

· Collaborates with Purchasing, Production Management and Quality Management on the trialing of new raw materials

· Collaborates with the project team and equipment vendors for any new equipment specifications and testing

Maintenance

· In collaboration with the Maintenance and Production Managers, provides recommendations for preventive, corrective and breakdown maintenance as deemed necessary for equipment to produce efficiently and with good quality.

Project Work

· The Process Engineer contributes to projects that affect their area of responsibility and engages and acts as a role model in the respective project team. The Process Engineer leads projects assigned to them as project manager and is responsible for appropriate, professional, and timely project work.

Leadership:

Company Policy

· The Process Engineer ensures company policies are followed without exception (i.e., “Dörken & I” handbook, Safety Policies/Procedures, etc.), and ensures strict adherence to the company’s Code of Ethics.

Instructions

· The Process Engineer is responsible for ensuring effective communication of new information to all affected employees in their area of responsibility.

· The Process Engineer provides support and is responsible for the generation of instructions or procedures, for the communication of instructions and procedures to all staff in their area of responsibility, and for the documentation of such communication.

Substitution during Absence

· In case of the Process Engineer’s absence either one of the Production Managers will substitute.

Social & Methodical Competence

Handling of Mistakes

· All employees have a responsibility to constructively make colleagues aware of mistakes or deviations from established standards.

· The Process Engineer communicates to the relevant Department Manager and Director of Operations, how a mistake or a deviation can be avoided going forward, and provides suitable information, technical information, etc. where required.

Personal Responsibility

· The Process Engineer is aware that their decisions will also affect other departments and team members of the organization.

· The Process Engineer strives for positive, outcome-oriented interaction.

Self-Reflection

· The Process Engineer accepts feedback and challenges their own actions and decisions.

· Constructive criticism is used as an opportunity for improvement.

Flexibility

· The Process Engineer adapts their customary or habitual thinking to new or changed situations, to effectively face new assignments and challenges.

Team Orientation

· At Dörken, we put great emphasis on team-oriented actions and on respectful interaction with one another.

· The Process Engineer must exemplify the Dörken values towards their co-workers and must consider the team aspect in their activities.

· We are considerate towards one another, and we support each other!

Organized Work

· The Process Engineer prioritizes, processes, and completes tasks in an organized fashion.

· The Process Engineer adheres to deadlines, and keeps an overview of tasks by documenting and following up on open/unfinished tasks.

Other Duties

· Per directive by the Director of Operations any other tasks/projects that fall into the Process Engineer’s responsibility or unfold as an operational necessity are to be addressed by the Process Engineer.

Reports to: Director of Operations

Direct Reports:

· None

Collaboration / Cooperation with:

· Production Managers (Flat Sheet and Dimple Sheet)

· Maintenance Manager

· Project Engineer/Manager

· Quality Manager

· Teamleaders, Operators

· Supply Chain Manager

· Warehouse Manager

· Purchaser

· EHS Manager

Qualifications:

Education

· Bachelor’s degree in a related field (mechanical, electrical, or chemical engineering; preferably specialized in plastics processing/technology)

· Suitable educational background in technical field and sufficient experience with production equipment and managerial duties

· Education/experience in Lean Manufacturing, Six Sigma, 5S, Kaizen, Kanban, TPM, etc. highly desired

Work Experience

· Minimum 3-5 years’ experience in a plastic process/industrial engineering position (e.g., extrusion, injection molding, slitting)

· Experience operating plant equipment safely and efficiently

· Experience/education in Lean Manufacturing, Six-sigma

· Strong aptitude for root cause analysis and troubleshooting operational issues

· Good understanding of regulatory requirements for operating production equipment

· Good understanding of ISO 9001 Quality Management System

Personal Profile

· Strong leadership, communication, negotiation, and presentation skills

· Hands-on data driven problem solver, with strong decision-making abilities based on data and/or experience.

· Ability to work under pressure in a fast-moving and fast-growing environment.

· Ability to work as a team player and effectively motivate others to achieve desired results.

· Acts as a technical resource to staff

· Demonstrates accountability and responsibility

· Advanced proficiency in

o ERP Systems

o MS-Office (Outlook, Word, Excel, Powerpoint)

o Statistical data analysis tools an asset (Minitab or other)

· Fluent in reading and writing English (German an asset)

· Valid driver’s license (Class G)

· Physically able to sit, stand and walk around for long periods at a time, and repeatedly lift up to 23 kg without assistance

Working Conditions:

· 8 am – 4.30 pm with high degree of flexibility to accommodate 24/7 operation

· 100% on-site at the company premises

· Available 24/7 for direction

· Overtime and/or weekend work where required

· Occasional travel may be required with advanced notice provided

Work Equipment:

· PC/Laptop

· Cell phone

Job Types: Full-time, Permanent

Additional pay:

• Bonus pay

Benefits:

• Casual dress
• Company events
• Dental care
• Disability insurance
• Employee assistance program
• Extended health care
• Life insurance
• On-site parking
• Paid time off
• RRSP match
• Store discount
• Vision care

Schedule:

• 8 hour shift
• Monday to Friday

Ability to commute/relocate:

• Beamsville, ON: reliably commute or plan to relocate before starting work (required)

Experience:

• plastic process/industrial engineering role: 3 years (required)

Language:

• English (required)

Work Location: In person