Process Engineer (New Castle)
Process Engineer FirmaPak New Castle, PA. BACKGROUND FirmaPak, Your Packaging Friend™, is a rapidly growing packaging manufacturer committed to helping our customers succeed with high-quality, reliable, and customizable packaging solutions. At FirmaPak, we are committed to providing a meaningful experience for all our team members. We invest in our people and our company, combining the best of a large organization with extensive resources and a business rooted in family values. Our strong culture fosters an environment that promotes growth — for our people, for our customers, and for our company. POSITION SUMMARY FirmaPak is expanding our New Castle, PA manufacturing operation, including the addition of plastic blow molding production, and we’re looking for an experienced Process Engineer – Blow Molding to play a key role in this growth. The Process Engineer will provide hands-on technical leadership for the installation, start-up, optimization, and ongoing performance of our blow molding processes and equipment. This individual will partner closely with Production and Maintenance to establish stable, efficient manufacturing processes that consistently deliver safe, high-quality products. In addition to process engineering responsibilities, this position will provide site-level quality support and leadership, with a strong focus on process and product quality, defect reduction, root-cause analysis, corrective actions, process controls, and continuous improvement. The successful candidate will bring direct blow molding process experience, ideally with extrusion blow molding and/or reheat stretch blow molding processes, strong technical and problem-solving capabilities, and an understanding of how equipment, tooling, materials, process parameters, and operating practices affect product quality and manufacturing performance. At FirmaPak, we understand customer needs, do what we say, and respond to solve problems — a unique combination that we call our Firm(aPak) handshake. Our Net Promoter Score indicates that our approach resonates with customers — our thrill is 6 times the industry average. We are excited to add a Process Engineer who shares our commitment to operational excellence, quality, and delivering for our customers. KEY ACCOUNTABILITIES Provide technical leadership for the installation, commissioning, start-up, validation, and optimization of plastic blow molding equipment and processes. Establish, document, and optimize blow molding process parameters to achieve consistent product quality, cycle times, efficiency, and throughput. Troubleshoot process-related issues involving equipment, tooling, materials, operating parameters, and finished-product quality. Partner closely with Maintenance to distinguish process-related issues from equipment-related issues and drive timely resolution. Monitor manufacturing processes and identify opportunities to improve scrap, yield, cycle time, downtime, quality, and overall equipment performance. Lead root-cause analysis and corrective action activities for process and product quality issues. Establish and maintain appropriate process controls, specifications, standard operating procedures, work instructions, and quality standards. Provide technical support to Production during new-product introductions, process changes, equipment modifications, and production issues. Analyze production and quality data to identify trends, recurring defects, and opportunities for process improvement. Support product inspections, quality investigations, nonconforming material disposition, corrective and preventive actions (CAPA), and customer quality concerns. Partner with Operations to ensure appropriate quality checks and controls are established and consistently followed on the production floor. Support internal and external quality audits and assist with maintaining required quality documentation and records. Train operators, technicians, and other team members on blow molding processes, process controls, quality requirements, troubleshooting, and standard work. Lead and participate in continuous improvement initiatives focused on safety, quality, productivity, waste reduction, and cost. Work with equipment manufacturers, tooling suppliers, material suppliers, and other technical resources to resolve process and quality issues. Support trials and validation of new materials, molds, tooling, equipment, and process changes. Develop and track key process and quality performance metrics and communicate results and improvement priorities to plant leadership. Promote a strong culture of quality, problem solving, accountability, and continuous improvement throughout the operation. KNOWLEDGE, SKILLS, AND ABILITIES Direct hands-on plastic blow molding process experience required; experience with extrusion blow molding and/or reheat stretch blow molding processes strongly preferred. Strong understanding of the blow molding process, including the relationship between equipment, tooling, resin/materials, process parameters, environmental conditions, and finished-product quality. 5 years of process engineering, manufacturing engineering, or comparable technical experience in a plastics manufacturing environment preferred. Demonstrated experience setting up, troubleshooting, optimizing, and improving blow molding processes. Strong understanding of common blow molding defects and demonstrated ability to identify root causes and implement sustainable corrective actions. Experience with process validation, process controls, standard work, and manufacturing documentation. Demonstrated experience with root-cause analysis, corrective actions, continuous improvement, and defect reduction. Working knowledge of quality systems and manufacturing quality principles. Experience supporting nonconforming product investigations, CAPA, audits, and customer quality issues preferred. Strong analytical skills with the ability to use production and quality data to identify trends and drive improvement. Experience with Lean Manufacturing, Six Sigma, SPC, DOE, or other structured problem-solving methodologies preferred. Working knowledge of automated manufacturing equipment, controls, and related auxiliary systems. Ability to read and interpret technical drawings, specifications, equipment documentation, and product requirements. Strong project management, organization, and prioritization skills. Strong communication and interpersonal skills with the ability to work effectively across Production, Maintenance, Quality, Operations, customers, and suppliers. Ability to train and coach employees on technical processes and quality requirements. Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Plastics Engineering, Industrial Engineering, or a related technical discipline preferred; significant directly relevant blow molding experience will be considered in lieu of a degree. Ability to work in a manufacturing environment and provide hands-on support on the production floor. FIRMAPAK DIFFERENCE FirmaPak offers a comprehensive benefits package, with benefit eligibility beginning the first of the month following your date of hire, including: Medical insurance, including an option for a company contribution to an employee HSA Dental and vision insurance 401(k) with company match Short-Term and Long-Term Disability Life Insurance Paid time off and holidays Internal promotion opportunities Bonuses based on company profitability Annual raises based on individual performance We know the importance of creating a strong culture, and we live by our BOTTLE Core Values: Be Customer Focused Ownership Mindset Teamwork Trusted Partner Learn Every Day Excellence Work Location: In person
