R&D Process Engineer

As an R&D Process Engineer at Footprint, you will be responsible for developing, evaluating, and improving process and equipment methods to enable on-time delivery of new products, cost reduction, decreased cycle and set-up times, quality, and efficiency improvements. You will utilize your statistical knowledge to drive improvement and process changes that improve performance, yield, cost, and efficiency. Additionally, you will be the single point of contact for equipment issues, concerns, and possible continuous throughput improvement ideas and/or projects. This role also involves setting up process parameters, monitoring equipment through regular testing, creating and overseeing standardized production procedures, and maintaining all documentation for products such as work instructions. You will work closely with cross-functional teams to determine ways to minimize operating costs and enhance equipment performance.

• Develop robust, reliable, effective, and efficient processes and equipment in support of business objectives.

• Establishing, providing, and maintaining the process engineering, technical and tooling functions and ensure that robust manufacturing processes are achieved to meet the plant’s productivity, delivery, quality, and safety objectives.
• Work to continually identify and implement advantaged processes and technologies.
• Participate in solving quality problems involving research and development equipment, and drive improvement and process changes that improve performance, yield, cost, and efficiency.
• Setting up process parameters, design of experiments and monitoring equipment by conducting regular testing.
• Create and oversee standardized production procedures and maintain all documentation for products, such as work instructions; and determining ways to minimize operating costs, such as equipment justification to enhance performance.  Furthermore role modeling the cycle of solving problems, documenting the changes, training personnel on the changes and proliferating those changes to the high-volume manufacturing sites.
• Produce high-quality documentation that meets applicable standards and is appropriate for its intended audience.
• Develop, establish, and ensure appropriate departmental standards, methods, policies, procedures, and documentation are in place and maintained.
• Modify or reengineer processes to increase throughput while maintaining or increasing the quality and accuracy of output.
• Serve as the lead when it comes to transferring new processes and technologies from the laboratory/bench/pilot scale into full production.
• Gather and analyze data and use that data to make recommendations.  This includes characterization of current process, quantifying/qualifying potential process improvements and leading validation efforts of newly implemented products/processes.
• Compile data, document work, and prepare reports for both technical and non-technical audiences.
• Coordinate and plan to ensure project work meets quality specifications and is delivered on schedule and within budgetary constraints.
• As needed, the engineer will travel to Footprint’s high volume manufacturing sites, suppliers, etc. for extended stays to support Footprint’s business objectives.
• Understand the development process, suggest improvements, and execute them to improve the development process.
• Performs all other duties and responsibilities as assigned or directed by manager.

Knowledge, Skills, and Abilities:

• Excellent written and oral communication skills.
• Ability to work on a cross-functional and diverse team.
• Ability to manage complexity, manage multiple priorities and prioritize accordingly.
• Flexibility and adaptability around shifting priorities in a fast-paced work environment to support 7 x 24 x 365 7 days a week, 24 hours a day, and 365-day operations.
• Strong analytical, creative thinking and problem-solving skills utilizing structured problem-solving techniques.
• The ability to drive projects and overcome any hurdles that are encountered from pilot to transfer to high volume manufacturing. 
• Strong interpersonal, cross-functional teamwork, process improvement and project management skills
• The ability to lead projects through to transfer to high volume manufacturing.
• Role model with safety and quality culture.
• The ability to collaborate with suppliers, establish a program with supplier for new equipment and deliver equipment on time and meeting specifications.
• The ability to keep projects on schedule to support footprint’s business objectives.
• Be able to learn new techniques, skill sets and apply them to their job scope.
• Advanced understanding of mathematics and engineering/science principles.
• Ability to deliver high quality documentation paying attention to detail

Applicants must possess the permanent right to work in the US.

Requirements: -

• Bachelor's degree in engineering, or equivalent
• 2+ years experience with process and equipment development or using advanced troubleshooting techniques on high volume manufacturing.
• Must be competent with Microsoft Office Suite, JMP, Statistics, Microsoft Access, and Microsoft Project
• Must be fluent in English and be able to travel both domestically and internationally.
• Preferred Minimum accredited lean six sigma green belt.
• Recognized technical abilities and practical experience with strong capabilities in the following areas:
• Theory/functionality of manufacturing systems and unit operations
• Continuous improvement techniques (Lean, TPM, Root Cause Analysis, Quick Changeover/SMED, Process Centerlines)
• Statistics and analytical methods, Process measurement and control
• Change management.

• Comprehensive Health Coverage: Including medical, prescription, dental, and vision care plans as well as HSA / FSA accounts.
• Insurance Protection: Basic term life, accidentals, short- and long-term disability, and voluntary life insurance coverage.
• Financial Security: Short and long-term disability plans, along with a 401(k) retirement plan.
• Time Off Support: Flexible time off program, paid holidays, sick leave, and parental leave benefits.
• Lifestyle Benefit: Voluntary Pet Insurance.

NOTE: This position is not eligible for a relocation benefit.