Process Engineer

Job Description

Job Description

Job Description

REHAU is seeking an experienced Process Engineer to join our manufacturing team in Cullman, Alabama. In this role, you will be responsible for optimizing extrusion processes, driving continuous improvement initiatives, and ensuring quality, safety, and efficiency across operations. You’ll collaborate closely with production, QA, maintenance, and R&D while also supporting new product development and equipment implementation.

This position offers the opportunity to travel both domestically and internationally, including working with our technical team internationally and key suppliers.

Key Responsibilities

• Process Optimization & Troubleshooting
• Analyze and improve extrusion parameters to enhance throughput, reduce waste, and maintain product specifications.
• Identify root causes of process deviations and defects; implement corrective and preventive actions.
• Quality Assurance Support
• Collaborate with QA to ensure products meet dimensional, mechanical, and visual standards.
• Support SPC, capability studies, and quality audits.
• New Equipment & Process Implementation
• Lead installation, commissioning, and validation of new equipment, tooling, and auxiliary systems.
• Develop and execute process qualification protocols and ensure smooth integration into operations.
• Time Studies & Cost Analysis
• Conduct time/motion studies to identify inefficiencies and optimize labor/machine utilization.
• Perform cost calculations for material, cycle times, energy, and labor to support continuous improvement and investment decisions.
• Documentation & Reporting
• Maintain accurate records of process settings, trials, and metrics.
• Prepare technical reports and presentations for management, audits, and cross-functional teams.
• Continuous Improvement & Technology Integration
• Lead/participate in Lean, Six Sigma, and Kaizen initiatives.
• Support automation, sensors, and data acquisition systems for real-time monitoring/control.
• Training & Support
• Train operators and technicians on SOPs, troubleshooting, and best practices.
• Provide technical support for daily operations and improvement projects.
• Safety & Compliance
• Ensure compliance with OSHA regulations, REHAU policies, and ISO standards.
• Promote a strong culture of safety and environmental responsibility.

Key Capabilities & Skills

Technical Skills

• Strong knowledge of polymer materials and extrusion behavior.
• Proficiency with extrusion equipment (extruders, dies, calibration tables, haul-offs).
• Familiarity with PLC/SCADA systems and data analysis tools.
• Understanding of rheology, heat transfer, and fluid dynamics.

Analytical & Problem-Solving

• Strong troubleshooting/root cause analysis.
• Ability to interpret process data, charts, and SPC/DOE results.
• Experience with FMEA and risk mitigation.

Project Management

• Ability to manage multiple projects and trials.
• Skilled in cross-functional collaboration and communication.

Soft Skills

• Strong communication and interpersonal skills.
• Detail-oriented, proactive, and able to work independently and in teams.

Educational Background Required:

• Bachelor’s Degree in Chemical Engineering, Mechanical Engineering, Polymer Science & Engineering, Materials Engineering, or Industrial Engineering (with relevant experience).
• 5–10 years of professional experience in process engineering, extrusion, or related manufacturing fields.

Preferred:

• Master’s Degree in Polymer Engineering, Process Engineering, or Manufacturing Systems Engineering.
• Coursework/experience in thermoplastics, extrusion, fluid mechanics, and heat transfer highly beneficial.

Certifications (Preferred, Not Required)

Technical & Industry

• Certified Manufacturing Engineer (CMfgE) – SME
• Six Sigma Green/Black Belt
• Lean Manufacturing Certification
• Extrusion Process Training (Polymer Center of Excellence, Penn College, SPE, etc.)

Quality & Compliance

• ISO 9001: Quality Management Systems
• ISO 14001: Environmental Management Systems
• OSHA Safety Training

Software & Tools

• PLC Programming & Automation Systems
• SPC Tools
• CAD/CAM or Simulation Software (SolidWorks, Moldflow, etc.)

Compensation

• Salary range: $100,000 – $120,000 annually , based on experience and qualifications.

Travel

• Occasional travel required, both domestic and international , to meet with suppliers and to collaborate with REHAU’s technical team in Germany.