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Process Engineer

AFL, a leading global fiber optics telecommunications company has an immediate opening for a Cable Process Engineer in Duncan, S.C. This individual will be part of a high-performing team responsible for improving process performance and implementing advanced manufacturing technologies. He/she will be responsible for actions and leading projects that improve processes and launch technologies that enable AFL to satisfy its customers and continue its strong growth.

The Process Engineer will be a member of the cable Technology team and will be dedicated to improving 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 Process Engineering Manager 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.

  • Lead efforts to improve performance and 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 ensure the process operates as required to meet product and customer specifications.
  • Provide hands-on engineering support for new product industrialization and initial production runs ensuring that the process is capable of safely producing a high-quality product that meets the specification, productivity, and cost targets. This would typically include specifying and documenting process parameters and tooling.
  • 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.
  • Interact with customers on technical and quality-related topics or issues. Lead all efforts to resolve customer complaints attributed to the process.
  • 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 process training and certification documentation to ensure 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.
  • Identify, justify, plan, and lead to continuous improvement, new product development, and capacity expansion projects.
  • Lead, participate, and support cross-functional project teams as assigned to achieve required objectives on-time and on-budget.
  • Work with the Technology Group to develop future products and processes including evaluating, selecting, and commissioning of process equipment.
KNOWLEDGE / SKILLS / COMPETENCIES                                                                                                                                                     
  • Demonstrated ability to solve processing/quality issues as well as improve process output through productivity improvements including changeover reductions and line speed optimization.
  • Proficient in advanced problem-solving including 6σ / DMAIC problems-solving.
  • Practical understanding of workplace 5S and lean manufacturing principles.
  • Driven by facts and analysis using advanced quantitative and qualitative techniques such as FMEA, DOE, MSA, and SPC.
  • Strong leader with the ability to build strong business partnerships.
  • 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.
  • A 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.
  • Solid understanding of quality management systems including current ISO 9001 standard.
  • Potential to grow into positions of increasing responsibility based on results and capabilities.
  • Intermediate or higher user of MS Office and statistical analysis software such as Minitab.
  • Strong analytical, time management and technical writing skills. 
REQUIREMENTS & EXPERIENCE                                                                                                                                                           
  • BS degree or higher in engineering or technology preferably in chemical, mechanical or industrial engineering.
  • 1-3 years of experience as a process, manufacturing, quality, or project engineer.
  • Preferential consideration will be given to those candidates with recent manufacturing experience in fiber optic cable, extrusion, and/or tube mill, metal forming and welding processes.
  • Experience leading teams and delivering results using 6σ / DMAIC problem-solving methodology.
  • Experience working in a lean/JIT/process-driven manufacturing environment.
  • Experience performing technical analysis on cable designs is a plus.
  • Able to support off-shift and/or weekend operations.
  • Green-belt, CQE or equivalent certification is a plus.
  • Able to travel up to 10%.