Process Engineering Manager Jobs in Johnson City, TN

JOB TITLE: Sr. Industrial Engineer

DEPARTMENT: Operations

REPORTS TO: Director of Operations

SUMMARY OF FUNCTION:

The Senior Industrial Engineer provides technical leadership and continuous improvement support for plastic extrusion manufacturing operations serving the natural gas distribution market. This role is responsible for initiating, developing, and implementing technical improvements that enhance manufacturing efficiency, process capability, product quality, cost performance, and overall operational effectiveness.

The Senior Industrial Engineer evaluates manufacturing processes, identifies and resolves technical issues, improves equipment and tooling performance, and supports operational excellence through Lean process improvement and data-driven KPI management. This position works cross-functionally with safety, quality, shipping, maintenance, and production reduce variation, increase throughput, and ensure manufacturing operations meet safety, quality, cost, and delivery requirements.

Duties and Responsibilities

• Provide technical leadership for plastic extrusion manufacturing processes, equipment performance, tooling systems, and process improvement initiatives.
• Assess current manufacturing operations to identify opportunities for improved safety, quality, productivity, material utilization, equipment efficiency, and cost reduction.
• Initiate, develop, and implement technical improvements that improve extrusion process capability, reduce variability, and support consistent product quality.
• Prevent, troubleshoot, and resolve technical problems related to extrusion processes, equipment performance, tooling, material flow, dimensional control, and production efficiency.
• Analyze process data, production metrics, scrap, downtime, throughput, labor utilization, and quality trends to identify root causes and implement corrective actions.
• Manage, develop, monitor, and improve key performance indicators related to manufacturing efficiency, equipment utilization, scrap reduction, labor productivity, quality performance, and overall operational performance.
• Lead continuous improvement activities using Lean manufacturing, 5S, standard work, visual management, root cause analysis, and other operational excellence tools.
• Partner with production and maintenance teams to improve manufacturing equipment efficiencies, reduce downtime, improve reliability, and support preventive maintenance strategies.
• Support tooling design, tooling performance, tooling maintenance, and changeover improvement activities to improve process stability, product quality, and operational efficiency.
• Develop and implement standardized processes, work instructions, process controls, and best practices to support repeatable and reliable extrusion operations.
• Evaluate process capability and manufacturing capacity to ensure equipment, tooling, labor, and process systems can meet current and future business requirements.
• Assist in the development and improvement of manufacturing layouts, material flow, labor standards, production methods, and workflow efficiency.
• Support new product introductions, process changes, equipment upgrades, tooling modifications, and capital improvement projects as required.
• Work closely with quality personnel to ensure manufacturing processes meet applicable product specifications, customer requirements, and industry expectations for natural gas distribution products.
• Train, coach, and support operators, technicians, and production leaders on process standards, quality requirements, equipment operation, troubleshooting methods, and continuous improvement practices.
• Lead or participate in cross-functional problem-solving teams focused on improving safety, product quality, cost, delivery, scrap, downtime, and customer satisfaction.
• Develop and maintain process documentation, technical reports, project plans, performance dashboards, and improvement action plans.
• Support cost reduction initiatives through improved material utilization, reduced rework and scrap, improved line rates, optimized labor efficiency, and better equipment performance.
• Ensure process improvements are implemented in a sustainable manner through standardization, training, verification, and ongoing KPI monitoring.
• Promote a culture of continuous improvement, accountability, teamwork, safety, and operational discipline throughout the manufacturing organization.
• Perform all other duties as directed by management

 EDUCATIONAL AND/OR EXPERIENCE REQUIREMENTS:

• Bachelor’s degree in engineering (industrial, mechanical, electrical) with a minimum of 5 years engineering experience in manufacturing environment
• Plastic pipe or profile extrusion experience preferred 
• Experience with plant safety practices and ergonomic analysis
• Lean manufacturing experience (Lean Six Green Belt+ preferred)
• Proficient in 2D & 3D CAD (On Shape) and Microsoft Office products
• Knowledge of AC/DC motors and drives, light electrical troubleshooting and design

OCCUPATIONAL AND/OR PHYSICAL REQUIREMENTS:

• Experience in Lean initiatives and processes; knowledge of ISO procedures, statistical methods and their applications
• Ability to organize and manage multiple priorities, project management skills
• Experience with root cause problem solving
• Experience with controls and instrumentation, ability to learn PLC programming and troubleshooting
• Ability to lift up to 50lbs without assistance, and to climb ladders, silos, roofs at varying heights
• Self-motivated, action oriented, hands-on individual with a keen interest / desire to learn
• Excellent communication skills (written and verbal)
• Ability to travel (up to 10%) within Canada, the US, and Internationally

WORKING CONDITIONS:

• Production floor (hot equipment, moving components, stepping over &/or bending under objects) and office environment
• Exposure to inside and outside elements

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