Sr. Manufacturing Process Engineer - Boise

This position is located in Boise, ID. Relocation assistance is available.

Position Summary:

• As a Senior Manufacturing Process Engineer, you will play a dual role, supporting day-to-day manufacturing operations while spearheading long-term continuous improvement efforts.  Your immediate focus will be troubleshooting and optimizing PVC extrusion processes with an emphasis on reducing scrap and downtime and improving material efficiencies.    

• By addressing these key areas, you will drive significant gains in operational efficiencies.  In this role, you will also lead strategic process improvements that align with Azek’s manufacturing goals, ensuring both short term operational success and long-term innovation. 

• You will utilize the relationship between material, equipment, and process to drive continuous improvement efforts.  Your expertise will be critical in identifying and resolving inefficiencies in the extrusion and downstream processes. 

• With a proactive approach to sustainable improvement, you will combine technical problem solving with process optimization, contributing to Azek’s commitment to operational excellence. 

Your primary duties and responsibilities will be: 

• Investigate and address daily operational challenges, including equipment failures, quality non-conformance, material performance, and processing issues.
• Conduct root cause analysis and implement corrective actions to address process deviations, non-conformances, and quality issues.
• Become a subject matter expert on PVC extrusion processing and support equipment within the facility.
• Analyze process data to identify opportunities for improvement within the operation.
• Develop, optimize, and troubleshoot manufacturing processes to improve efficiency, quality, and throughput.
• Lead cross-functional continuous improvement initiatives to identify and implement process improvements that will increase productivity, reduce costs, and improve quality
• Recommend capital improvement projects such as equipment upgrades and automation solutions to enhance productivity and reduce costs.
• Evaluate the performance of existing process tooling and work to improve dimensional tolerances, output, yield, and downtime.
• Work with tooling and equipment vendors to troubleshoot process and tooling problems.
• Provide technical expertise and support for equipment selection, installation, calibration, tooling, and maintenance.
• Collaborate with cross-functional teams, including production, engineering, quality assurance, and supply chain, to ensure alignment of manufacturing processes with business objectives.
• Establish and maintain standard operating procedures (SOPs), work instructions, and process documentation.
• Train and mentor production staff on new processes, technologies, and best practices.
• Stay current on industry trends, emerging technologies, and best practices in manufacturing process engineering.

We believe the successful candidate will have: 

• BS degree in Mechanical, Chemical or similar engineering discipline.
• Investigate and address daily operational challenges, including equipment failures, quality non-conformance, material performance, and processing issues.
• Conduct root cause analysis and implement corrective actions to address process deviations, non-conformances, and quality issues.
• Become a subject matter expert on PVC extrusion processing and support equipment within the facility.
• Analyze process data to identify opportunities for improvement within the operation.
• Develop, optimize, and troubleshoot manufacturing processes to improve efficiency, quality, and throughput.
• Lead cross-functional continuous improvement initiatives to identify and implement process improvements that will increase productivity, reduce costs, and improve quality
• Recommend capital improvement projects such as equipment upgrades and automation solutions to enhance productivity and reduce costs.
• Evaluate the performance of existing process tooling and work to improve dimensional tolerances, output, yield, and downtime.
• Work with tooling and equipment vendors to troubleshoot process and tooling problems.
• Provide technical expertise and support for equipment selection, installation, calibration, tooling, and maintenance.
• Collaborate with cross-functional teams, including production, engineering, quality assurance, and supply chain, to ensure alignment of manufacturing processes with business objectives.
• Establish and maintain standard operating procedures (SOPs), work instructions, and process documentation.
• Train and mentor production staff on new processes, technologies, and best practices.
• Stay current on industry trends, emerging technologies, and best practices in manufacturing process engineering.

Core Competencies:

• Engineering Cost Savings, Analytical Skills, Lean Six Sigma, Manufacturing Systems, Production Processes, Extrusion, Problem Solving, Manufacturing Operations
• Candidates should be data driven decision makers.  This role will work on the factory floor to increase machine production yields, drive improvements to quality standards. Assess machine issues and take proactive corrective action.  Training of operators. 
• The Wilmington plant is a 24/7 production operation.  Incumbent will be on call. 
• Candidate soft skills:  good multitasking, experienced working well with vendors and contractors. Analytical. Good follow-up. Experience with electrical and mechanical troubleshooting.  Strong safety mindset.  Able to red flag contractor safety issues.

About The Azek Company

The AZEK Company is committed to innovating, inspiring, reinventing, revolutionizing and leading our industry to create a more sustainable future. We offer low-maintenance, beautiful outdoor living products leveraging innovations in material science to offer our customers world-class, environmentally sustainable solutions. Headquartered in Chicago’s Fulton Market neighborhood, The AZEK Company is nestled in the same thriving business district that houses other leading corporations such as Google, Dyson, and Glassdoor. The AZEK Company also operates manufacturing and recycling facilities in Ohio, Pennsylvania, Idaho, Georgia, Nevada, New Jersey, Michigan, Minnesota, and Texas. CREATING GOODS THAT DO GOOD We wholeheartedly embrace a responsibility to sustainability and seek to always act with purpose. We are committed to pursuing initiatives that positively impact our products, our people and our planet. Like leveraging our R&D strengths to introduce products that increasingly utilize recycled materials and tapping our culture to positively impact employees, customers and communities alike. And, committing to set ambitious targets like using 1 billion pounds of recycled materi...al annually in the manufacturing of our products and reducing the carbon footprint across our value chain in alignment with climate science. Our success is fueled by the ideas and dedication of our team and we are committed to providing an equitable and inclusive workplace where diversity of all kinds is sought out, valued, respected and appreciated. We have an unwavering customer-centric focus. Our responsibility is to understand customer expectations, then surpass them. We are also committed to working with business partners and suppliers whose values and practices mirror our own. At The AZEK Company, we look at the full-circle and we bring things full-circle. Why? Because, we seek to revolutionize outdoor living to create a more sustainable future.

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