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Process Engineer
Job#: 169675
Positions: 1
Posted: 01/28/2013
Job Type: Full Time
Location: Greenville/Spartanburg, SC
Department: ACS - Operations
Category: Engineering
Salary: Salary
Benefits: Full-time Benefits
Business Unit: ACS
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Job Description

COMPANY OVERVIEW                                                                                                            

AFL Telecommunications is an industry leader in providing fiber optic products, engineering expertise and integrated services to the telecommunications industry.  We manufacture, engineer, and install the fiber optic products and equipment that communications providers need to provide high-speed voice, video and data services to their customers. Our extensive experience in both design and application crosses all markets, from Telecommunications, Broadband and Wireless, to Electric Utility, OEM, Enterprise and Private Networks.


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JOB DESCRIPTION                                                                                                                    

The Process Engineer will be a member of the cable manufacturing leadership team and will be dedicated to improving extrusion process performance.  He/She will be diligent in applying their engineering skills and experience, driven by data and facts, and comfortable leading teams of operators, technicians, and engineers through projects and problem-solving exercises.


He/She will be accountable for delivering tangible results in support of business plan objectives by implementing improvements, supporting new product industrialization, improving capacity utilization, and managing continuous improvement efforts. 


The position will report to the Manufacturing Manager or designee and may be assigned to specific projects and/or responsibility for all aspects of one or more production processes including the assigned technicians and/or operators.


The position is located at our Duncan, SC manufacturing facility which operates on a seven day, twenty-four schedule.  To support operations, off-shift and weekend work will be required at times to meet project deadlines or support operational requirements.


The successful candidate must meet the all of the knowledge, skills, competencies, and experience requirements outlined below.



JOB RESPONSIBILITIES                                                                                                            

  • Manage daily process quality performance to include the investigation of issues, the disposition of items with defects, and the initiation of corrective and preventative actions.
  • Lead efforts to resolve quality issues by rigorously applying methodical problem solving techniques to contain the problem, identify root causes, and implement sustainable corrective actions.
  • Define, measure, and monitor process performance metrics (OEE, Defect Rates, Process RFT, Cp, and Cpk) to identify opportunities for improvement.
  • Define critical-to-quality process parameters (speeds, temperatures, pressures) using a Process FMEA or other analytical tools.  Then implement measurement and control systems to insure the process operates as required to meet product and customer specifications.
  • Provide hands-on engineering support for new product industrialization and initial production runs insuring that the process is capable of safely producing high quality product that meets specification, productivity, and cost targets.  This would typically include specifying and documenting process parameters and tooling.
  • Lead all efforts to resolve customer complaints attributed to assigned production processes.
  • Work with internal and external suppliers of materials, equipment, and services to execute projects, resolve problems, and improve processes.
  • Select, design, modify, and maintain tooling, fixtures, and equipment as needed to improve safety, quality, throughput, and productivity.
  • Develop and maintain extrusion process training and certification documentation to insure that operators clearly understand all position requirements.
  • Improve housekeeping and safety by applying the 5S principles and participating in audit programs.
  • Support business plan objectives to increase productivity, reduce waste, improve quality, and enhance safety.


KNOWLEDGE / SKILLS / COMPETENCIES                                                                             

  • Strong knowledge of extrusion processes using the following materials: PVDF, Nylon, PVC, MDPE, HDPE, LSOH, FRPE, CPE, PU, TPU, PBT, and others.
  • Demonstrated ability to solve extrusion processing /quality issues as well as improve process output through productivity improvements including changeover reductions and line speed optimization.
  • Self-starter with integrity and confidence who strives to achieve even the most challenging objectives with limited supervision.
  • Team player with well developed interpersonal skills that is comfortable working in a fast-paced, dynamic, cross-functional, and multi-cultural environment.
  • Results-oriented professional that is comfortable in a challenging professional environment where complex problem solving is required.
  • Strong communicator with the ability to convey complex issues in simple terms to all levels of the organization.
  • Driven by facts and analysis using advanced quantitative and qualitative techniques such as FMEA, DOE, MSA, and SPC.
  • Solid understanding of quality management systems including current ISO 9001 standard.
  • Practical understanding of workplace 5S and lean manufacturing principles.
  • Potential to grow into positions of increasing responsibility based on results and capabilities.
  • User of manufacturing related modules in Oracle R12.
  • Intermediate or higher user of MS Office and statistical analysis software such as Minitab.
  • Strong analytical, time management and technical writing skills.
  • BS degree or higher in engineering or technology preferably in chemical, mechanical or industrial engineering.
  • Three plus years of experience as an extrusion process, manufacturing, quality, or project engineer.
  • Preferential consideration will be given to those candidates with recent manufacturing experience in fiber optic cable extrusion.
  • Experience working in a lean/JIT/process-driven manufacturing environment.
  • Able to support off-shift and/or weekend operations.
  • Green-belt, CQE or equivalent certification is a plus.
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