Process Engineer (Leominster, MA) - IPL

IPL is a global leading sustainable packaging solutions provider that manufactures specialty rigid packaging products used in the food, consumer, agricultural, logistics and environmental markets. We have over 2,500 colleagues in 18 manufacturing facilities, one corporate office and two R&D facilities across Canada, the U.S., Ireland, the U.K., Belgium and China. IPL operates in a fast paced and dynamic environment and has significand growth plans acquiring four business in the last year.

Read more about our story at: www.iplglobal.com

Location: This role can be based out of any IPL NA site.

• Forsyth, GA
• Leominster, MA
• Phoenix, AZ
• Fairfield, CA
• Shelbyville, KY
• Union Gap, WA
• Dayton, OH
• Lee's Summit, MO

Roles & Responsibilities

• Analyze and evaluate the existing manufacturing processes to identify areas of improvement such as cycle time reduction, scrap reduction, and productivity enhancement.
• Collaborate with cross-functional teams, including product development and operations to develop and implement new manufacturing processes for production by conducting feasibility studies, designing process flows, implementing scientific molding principles, optimizing cycle times, and ensuring product quality and consistency.
• Establish and maintain process standards for the Division including defining practices, standard operating procedures (SOP's), process documentation, and work instructions to ensure consistency, quality, and compliance across all manufacturing processes.
• Develop and implement strategies to optimize the processes and improve overall efficiency across the division.
• Collaborate with the Quality assurance team to establish and maintain quality control measures.
• Develop and implement process controls, inspection procedures, and testing protocols to ensure consistent and high-quality output.
• Drive continuous improvement initiatives aimed at enhancing productivity, reducing waste, improving quality, and optimizing process efficiency.
• Utilize tools such as lean manufacturing, Six Sigma, and Kizan to identify and implement process enhancements, cost-saving measures, and waste reduction strategies and measure the impact of process enhancements across the Division.
• Collaborate with maintenance and tooling teams to ensure proper maintenance and functionality of equipment and tooling used across the Division.
• Identify opportunities for equipment upgrades or replacements to enhance productivity and quality.
• Develop and implement a preventative maintenance program for the infrastructure (including buildings and equipment), including scheduled inspections, maintenance tasks, and calibration activities to proactively address potential issues and minimize unplanned downtime.
• Develop and deliver training programs for operators, technicians, and other personnel involved in the manufacturing processes.
• Provide Technical Support and troubleshooting assistance to the production sites within the Division.
• Collaborate with site teams to address process-related issues, resolve equipment malfunctions, and optimize production output.
• Offer guidance on process improvements and assist in implementing changes.
• Collect and analyze process data, including production metrics, quality data, and equipment performance.
• Generate reports and provide insights to management on process performance, identifying trends, and recommending actions for improvement.
• Ensure compliance in accordance with health, safety, and environmental policies and procedures to safeguard the well-being of staff and visitors.
• Provide regular, consistent, and transparent communication and interaction with the divisional leadership team about engineering activities, potential threats, opportunities, and recommended actions.
• Ability to role model our Values.

Additional information (including specialized qualifications / skills)

• Bachelor’s degree in Engineering, preferably in Plastics Engineering, a related field, or proven work experience.
• At least 10 years experience in plastics injection manufacturing, preferably supporting multiple sites.
• Able to successfully lead and implement change, structure, and process and take a common-sense approach to encourage continual cultural, technological, and operational transformation.
• Strong interpersonal skills and the ability to collaborate effectively with diverse individuals.
• Knowledge of manufacturing best practices and industry standards.
• Excellent problem-solving skills.
• Strong attention to detail.
• Ability to prioritize tasks.
• Ability to effectively work with cross-functional teams.
• ERP experience (IFS advantageous but not essential).
• Experience in a Private Equity (PE) environment is advantageous.
• Ability to travel as needed.