We are seeking an experienced Process Improvement Engineer with a strong background in carded needle-punch nonwoven manufacturing and fiber processing. This role will focus on improving the performance, consistency, efficiency, and quality of carded needle-punch nonwoven manufacturing processes. The successful candidate should understand how fiber characteristics and processing conditions affect carding, needle-punching and final nonwoven product properties. This is a hands-on manufacturing position requiring significant interaction with production equipment, operators, technicians, and engineering teams.
Key Responsibilities
- Lead process improvement initiatives for carded needle-punch nonwoven manufacturing processes.
- Optimize processes from fiber preparation and blending through carding, web formation, crosslapping, needle punching, and finishing.
- Troubleshoot issues related to fiber opening, blending, fiber distribution, web uniformity, basis weight, thickness, density, and product consistency.
- Optimize carding and web-forming conditions to achieve consistent fiber distribution, orientation, web weight, and uniformity.
- Optimize needle-punch parameters including needle density, penetration depth, punch frequency, stroke, and line speed.
- Evaluate the impact of fiber type, fiber length, denier, crimp, finish, blend ratios, and recycled content on manufacturing performance.
- Conduct plant trials and process experiments involving new fibers, fiber blends, equipment settings, and process conditions.
- Identify and eliminate root causes of scrap, defects, downtime, rework, and process variation.
- Analyze manufacturing data to identify opportunities to improve throughput, yield, quality, and material utilization.
- Establish and maintain appropriate process windows, operating standards, and process controls.
- Use structured problem-solving methodologies including Root Cause Analysis, 5-Why, Fishbone, SPC, DOE, Lean, and Six Sigma tools.
- Work with Maintenance and Engineering on equipment modifications and improvements.
- Support new product development and commercialization by establishing repeatable manufacturing processes.
- Develop and maintain SOPs, work instructions, process specifications, and control plans.
- Train and support production personnel on optimized process conditions and standard operating procedures.
- Track and quantify process improvement results, including cost savings, scrap reduction, productivity, yield, and capacity improvements.
Requirements
- Bachelor's degree in Textile Engineering, Chemical Engineering, Mechanical Engineering, Materials Science, Manufacturing Engineering, or a related technical field.
- 5+ years of experience in process improvement, process engineering, or manufacturing engineering.
- Strong hands-on experience in nonwoven manufacturing and fiber processing.
- Direct experience with carded needle-punch nonwoven processes.
- Strong understanding of fiber processing, carding and needle punching.
- Experience working with synthetic fibers and fiber blends, such as polyester/PET, polypropylene, or recycled fibers.
- Experience troubleshooting manufacturing problems directly on the production floor.
- Demonstrated experience improving manufacturing throughput, yield, quality, process capability, and material utilization.
- Strong analytical and problem-solving skills with the ability to use manufacturing data to identify root causes and implement solutions.
- Experience with Lean Manufacturing, Six Sigma, SPC, DOE, and root-cause analysis.
- Strong communication and collaboration skills. Ability to work effectively with Production, Operations, Maintenance, Quality, R&D, and Engineering teams.