Process Engineer

Job Title: Process Engineer

Job Code: 0602

Department: Foam

Open Date: 05-Feb-25

Reports To: Foam Operations Manager

Job Purpose

Responsible for ensuring the smooth operation of the foam plant process. This includes all areas of the foam chemistry, process optimization, trouble shooting. quality, scrap, rework and downtime.

Duties and responsibilities

1) Knowledge of the foam reactivity profile of a given system. Need to understand, Cream Time, Gel Time, End of Rise, Top of Cup, % Recession (Relapse), Density, Material Viscosity.

2) Ability to develop robot pour programs patterns for effective foam distribution. Understanding of the inputs and outputs within the programs associated to mix head functions, part counters, area release, collision protection etc. Knowledge of robotic functions, safety items, ability to trouble shooting fault errors.

3) Maintain and understand the importance of critical process variables, including chemical stream mixing pressures, temperatures, tooling temperatures, seal-off and venting conditions, and internal mold pressures.

4) Establish and maintain foam shot size, index and flow rates to optimize foam physical characteristics and product quality.

5) Understanding the basis of formulation changes (Index, Ratio), and how it correlates to I.F.D. (Indentation Force Deflection) results.

6) Understanding of the basic function of a mix head and how mix quality can be optimized through mix head vernier adjustments, orifice sizing, pressures and flow rate.

7) Maintain and understand PLC carrier function variable settings. Able to diagnose carrier malfunctions and recommend corrective actions.

8) Ability to effectively trouble shoot mold related defects due to temperatures out of spec, seal-off effectiveness and affects of over and under venting.

9) Knowledge of flow rates, ratios, and pressures and how they effect each other, and the level of chemical mix.

10) Ability to update manual pour setup in order to reduce chemical stream throughput variation as well as stabilizing individual stream pressures and improving overall mixing consistency.

11) Good working knowledge of the Tank Farm setup and function. Able to trouble shoot system failures and coordinate resolution through support staff if required.

12) Actively participate in the clean up of chemical spills as required.

13) Good working knowledge of overall foam plant operations. Able to trouble shoot a variety of different types of processing equipment with Electrical, Mechanical and Mold Maintenance departments as required.

14) Ability to communicate effectively with a variety of departments, in order to achieve desired goals and objectives set forth my management.

15) Responsible for achieving productivity and efficiency percentages as set by the Production Manager. 16) Ensure that all employees work in a safe manner. 17) Develop and maintain a team-oriented atmosphere at all times.

18) Ensure that all Company safety procedures are strictly adhered to at all times.

19) Address all safety concerns either raised by workers or from safety audits. Advise workers of any potential or actual hazard.

20) Complete Accident Investigations and ensure corrective measures are taken.

21) Ensure service parts are produced in a a timely manner and are identified as service parts.

22) Submit daily shift notes that identify critical events that effected hitting operational targets.

23) Ensure all first off and new forms from the lab are responded to in a timely manner. Tools that are producing nonconforming parts must be segregated and identified.

Duties and responsibilities -Standards

A) Achieve departmental KOI's as set by the Department Manager.

B) Follow all guidelines in accordance with ISO-14001 & TS 16949 requirements.

C) Maintain safety and housekeeping at all times.

D) Other duties as assigned.

Safety, Health and Environmental Responsibilities - Standards

A) Ensure that Health and Safety and Environmental standards are adhered to in accordance to the Magna Charter, Company Policies & Procedures and the Occupational Health and Safety Act.

B) As required participate in plant safety, health and environmental programs.

Qualifications

Technology Diploma or University Degree in Chemical or Mechanical Engineering discipline, or equivalent Processing experience required. Minimum 2 years processing experience in a JIT environment preferred

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