Process Engineer

Company Summary

Wahl Refractory Solutions is an industry-leading provider of innovative precast refractory solutions to the Steel, Nonferrous, and Minerals Processing industries. Wahl develops its own proprietary refractory formulations for use in its manufacturing facility in Fremont, Ohio. Wahl has a long history of ground-breaking, innovative refractory solutions that have been adopted by industry World-wide.

Job Summary

The Process Engineer position plays a key role in manufacturing, optimizing operational procedures to improve safety, efficiency, quality, and cost. The Process Engineer works with Quality, Manufacturing, and Engineering/Design personnel to design and implement processes, identify techniques, tools and equipment that improve Wahl’s ability to provide quality innovative products to our customers that are easy to manufacture repeatedly. The mantra “safer, faster, better, cheaper” applies to their daily work.

Essential Duties and Responsibilities

The following is an outline of the basic duties and responsibilities of the above-titled position. It describes the duties and responsibilities in the broad scope, and is not intended to be all-inclusive, and does not constitute a contract of employment. Individual(s) in this position may from time-to-time be assigned other duties as appropriate.

Administrative

• Adherence to all Wahl Health & Safety requirements, to remain up to date on all applicable training to maintain compliance.
• Adherence to all applicable processes and procedures as defined by Wahl’s Quality System, to remain up to date on all applicable training to maintain compliance.
• Manage and maintain a professional demeanor with strong housekeeping and organizational skills
• Maintain all tools, machinery, measurement, and test equipment/apparatus in a clean, secured, and organized manner.
• Maintain strict confidentiality protocols of product information and specifications, and other confidential and trade secret information.

Process Design & Continuous Improvement

• Drive process improvements to create efficiencies in manufacturing processes to improve safety, reduce direct and overhead costs, improve quality, and simplify operations.
• Apply permanent solutions to sustain corrective actions.
• Help transition manufacturing to a visual factory.

Troubleshooting & Manufacturing Support

• Support manufacturing and engineering in mold design, repair and improvement.
• Troubleshoot manufacturing issues and provide timely solutions relating to process equipment, molds and forms.
• Member of 1st Piece inspection team for molds and cast parts.
• Employ appropriate Lean techniques through out the facility to improve flow, aid in mistake proofing and improve the working environment for employees.

Technology Implementation

• Investigate advances in applicable manufacturing techniques, methods, materials, equipment, etc. that could provide benefit to Wahl in all areas of manufacturing, with the goals of improving safety, quality, cost, and productivity.
• Lead the acquisition, procurement, installation, and start-up of new equipment and technologies in manufacturing.
• Construct the appropriate training programs and update all related procedures that incorporate process changes.

Quality

• Routinely participate in weekly Customer Complaint Call and lead applicable investigations, develop and implement corrective and preventative actions on non-conforming products as appropriate.
• Conduct Root Cause Analyses and report with recommendations.
• Develop, implement, and continuously improve visual work instructions for all relevant processes in the plant.
• Lead the training of the appropriate manufacturing personnel on visual work instructions.
• Leads the daily plant reject walk and communicate relevant feedback from customers to production team.

Qualifications

To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the education, training, knowledge, experience, skill, and/or ability required.

a. Minimum Education & Background

• B.S. in Mechanical Engineering, Industrial Engineering, Chemical Engineering, or related technical field of study.
• 2-5 years of relevant work experience preferred.
• Strong technical and problem-solving skills.

b. Language & Communication Skills

• Fluent in English.
• Ability to read procedures, technical drawings and print, equipment manuals/specifications and other documents in English.
• Ability to effectively produce and present information to management, customers, and/or other groups in a clear and concise manner that can be understood by technically-trained and non-technically trained people alike.
• Ability to produce Visual Work Instructions and other quality documents that are well constructed, complete, and easy to understand.

c. Analytical ,Computer & Mathematics Skills

• Critical thinking.
• Strong ability to identify and observe a situation, collect data, analyze and problem solve.
• Ability to apply mathematical operations to such tasks as determination of test reliability and validity, analysis of variance, correlation techniques.
• Apply analytical techniques for root cause analysis like 5 Why’s, Fishbone diagrams, Design of Experiments, etc.
• Well versed with Microsoft Office (Excel, Word, PowerPoint, etc) software.

d. Physical Demands

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions.

• While performing the duties of this job, the employee is regularly required to stand; use hands to handle or feel; reach with hands and arms.
• Ability to lift up to 65 lbs.

e. Work Environment

• While performing the duties of this job, the employee will regularly be in a manufacturing environment.
• Exposure to airborne particles, dust and dirt. The noise level in the work environment is usually quiet to moderate with occasional loud noise due to running equipment.
• Regular exposure to cold and heat.