Bonnell Aluminum is looking for a self-motivated Process Manufacturing Engineer for the Carthage, Tennessee facility, who will report to the Engineering Manager.  Ideal candidate will develop an effective working relationship with the area department manager to facilitate coordination and prioritization of work for that area of responsibility.  The work will involve projects related to process, productivity, cost, safety and quality improvements.   Must be ready to work as part of a team and independently as needed.

PRIMARY RESPONSIBILITIES:

Duties and Tasks/Essential Functions: 

Technology and Process Area Expert

• Develop in-depth technical understanding of the operation and maintenance requirements for the equipment and process.
• Develop capital project process and execution expertise.
• Develop user-level expertise in current and future ERP/MES (Enterprise Resource Planning/Manufacturing Execution System)

Responsibilities/Scope/Complexity

• Must demonstrate a strong commitment to safety procedures and lead or be involved in identifying and implementing safety improvement ideas.
• Ability to use work breakdown structure to effectively manage small and large projects.
• Support operations in reviewing equipment efficiencies, downtime, and scrap.
• Make recommendations for improvements to equipment and operating procedures to improve productivity.
• Provide technical and engineering support in the ongoing operation and maintenance of existing equipment.
• Provide oversight of vendors and contractors as needed for specific projects.
• Makes decisions within known work processes and make recommendations for improvements using a data-based approach (Sig Sigma, Lean, etc.).
• Ability to run routine data analysis.
• Positive and productive interactions with internal and external customers and suppliers.

Continuous Improvement (Operational Excellence)

Ownership and execution of continuous improvements in the area of responsibility, which will include collaborative development of a prioritized list of CI projects for each process and sub-processes for each technical area.

Execution of Continuous Improvement projects based on Division, Plant and Area of Responsibility targets/goals.   Tracking and overall facilitation of focused activities relating to:

• Safety Risk Reductions
• Quality Improvements
• Productivity Improvements 
• Cost Reductions - Annual area cost reduction, tracking and auditing
• Revenue Enhancements
• Capability Improvements
• General Efficiency Improvements (Time, Inventory, Motion, Waiting, Over Processing, Defects)

Lean Events (Project, Kaizen, Burst, Do-it)

• Facilitate Lean Events
• Conduct Team Member training
• Key resource for area team leaders, including team leader CI training
• Overall event scheduling and coordination 
• Use of the DMAIC process for continuous improvement projects
• Responsible for all project status briefs and report-outs.
• Responsible for collecting, evaluating, prioritizing, and executing waste stoppers submittals from operators and recommending for possible recognition.

Capital Project Management

• Capital justifications for small/large projects
• Project write-up and submittal
• Technology Specifications
• Construction/Installation Management
• Contractor Management 
• Start-up and Commissioning
• Operations Training & Qualification
• Systems, Safety, Quality, Productivity, and Reliability assessments and mitigations

REQUIREMENTS

Educational and Experience Requirements

• Must have a Mechanical Engineering degree or similar discipline from an accredited college with a GPA equivalent to or greater than 3.0 on a 4.0 scale.
• 5-7 years of experience in maintenance, engineering, and/or technical activities in a manufacturing environment. Knowledge of Paint Line, Anodizing, Casting, and Aluminum Extrusion processes are desirable.
• Familiarity with PLCs and various machine programming languages required; ability to program machines desirable. Automation and robotics experience is a plus.
• Lean Six Sigma Green Belt or Black Belt desirable
• Ability to travel as required

Skills/Knowledge

• Subject Matter Expert - Developing subject matter knowledge and expertise
• Leadership - Developing leadership skills
• Critical Thinking - Tactical critical thinking
• Work Process Management - Learning roles and processes
• Communication Skills - Ability to communicate effectively verbally and written, including presentations.

Required Tools/Software Knowledge

• Microsoft Office suite including Word, Excel, Outlook and PowerPoint
• Project Management Software
• Quality Companion and Minitab
• Working knowledge of J.D. Edwards data queries would be a plus
• AutoCAD modeling and drawing creation

COMPENSATION:

• Salary:   Based on experience and degree
• Employee Benefits:
  • Paid Vacation
  • Medical, Dental and Life Insurance
  • 401 (K) plan
  • On-site Clinic
  • On-site Fitness Center