Senior Process Engineer

RESPONSIBILITIES

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The Senior Process Engineer is responsible for developing and improving manufacturing processes to achieve safety, quality, delivery, and cost standards of the business. Utilization of skills to continuously improve the manufacturing process eliminating wasteful activities. Individual is expected to interact in collaboration with manufacturing and engineering teams in Hamden and global facilities to achieve business goals and objectives. Must be a hands-on, growth-oriented individual who has an internal drive to improve current processes and continually drive team to perform to maximum potential.

• Serve as the technical leader for extrusion processes, ensuring coating quality, dimensional accuracy, and compliance with industry standards.
• Communicate effectively and maintain a strong presence on the production floor, partnering with operators to resolve process issues, reduce scrap, and improve throughput.
• Lead root cause analysis and implement corrective actions to minimize downtime and enhance process reliability.
• Design, test, and deploy tooling, automation, and auxiliary equipment to support high-speed extrusion operations.
• Develop and maintain work instructions, process documentation, and assembly line standards.
• Collaborate with suppliers and equipment manufacturers to specify, procure, and validate new technologies.
• Analyze process cycle times, yields, and efficiencies; identify opportunities for cost reduction and productivity improvement.
• Drive risk assessments, DFMEA, and safety evaluations to ensure compliance and mitigate operational hazards.
• Champion lean manufacturing principles and act as an agent of change in a fast-paced, global environment.

Required Qualifications:

• Bachelor's degree in Engineering (Plastics, Mechanical, or related discipline).
• 10+ years of experience in high-speed, automated manufacturing environments; wire and cable extrusion experience strongly preferred.
• Proven expertise in extrusion processes and auxiliary equipment (pay-off, take-up, vacuum sizers, melt pumps).
• Strong analytical and problem-solving skills; ability to resolve complex technical issues with minimal supervision.
• Working knowledge in CAD tools (Creo, SolidWorks) and MS Office Suite.
• Excellent communication skills with ability to collaborate across global teams.

Preferred Qualifications:

• Advanced degree in Engineering or related field.
• Experience with automation systems and tooling design.
• Lean manufacturing knowledge or Six Sigma certification.
• Bilingual (Spanish and/or Mandarin).
• Familiarity with DFMEA, risk assessment, and continuous improvement methodologies.