Process Engineer

A well established company is looking for a Process Engineer. Requirements: ·        Bachelor’s Degree or National Diploma in Chemical Engineering, Mechanical Engineering, Industrial Engineering, or Polymer Engineering. ·        Relevant qualificati...

Key Responsibilities A. Process Development and Optimisation

• Develop, implement and optimise manufacturing processes for injection moulding, blow moulding and PET production. • Establish, document and maintain optimal machine settings and processing parameters for each product and mould. • Conduct machine and process trials for new products, moulds, materials and equipment. • Identify opportunities to improve cycle times, machine efficiency, output and overall production performance. • Troubleshoot process-related issues and implement corrective actions to prevent recurring problems. • Optimise start-up procedures, changeovers and production processes to reduce downtime. • Ensure processes are repeatable, stable and capable of consistently producing products within specification. B. Production Efficiency and Cost Reduction

• Monitor and improve Overall Equipment Effectiveness (OEE), machine utilisation and production output. • Identify and implement opportunities to reduce scrap, material wastage, rework and production losses. • Analyse production data to identify inefficiencies and implement measurable improvements. • Improve cycle times and productivity without compromising product quality. • Assist in reducing manufacturing costs through improved process control, material utilisation and production efficiencies. • Work with production teams to achieve daily, weekly and monthly production targets. • Investigate production bottlenecks and recommend practical solutions. C. Quality Control and Process Compliance

• Work closely with the Quality Department to ensure products meet approved specifications and customer requirements. • Investigate quality defects, including dimensional variations, flash, short shots, warpage, leaks, weight variations and other process-related defects. • Conduct root-cause analysis and implement corrective and preventive actions. • Establish and maintain process control standards and inspection requirements. • Ensure process parameters and production records are accurately documented. • Support internal, customer and certification audits where required. • Ensure manufacturing processes comply with applicable food-contact packaging requirements and the company's quality management systems, including FSSC 22000 requirements where relevant. D. Machine, Mould and Equipment Performance

• Work closely with the Toolroom and Maintenance Departments to improve machine and mould performance. • Assist with mould commissioning, machine setup and production trials. • Identify recurring mould-related and machine-related problems and recommend permanent corrective actions. • Monitor the performance of moulds, machines and auxiliary equipment. • Assist with the evaluation and commissioning of new machinery, moulds and production equipment. • Develop and maintain standard operating procedures for machine setup, process control and production changeovers. • Ensure machine settings and process parameters are appropriately controlled and protected against unauthorised changes. E. Raw Materials and Material Management

• Optimise the processing of raw materials, including PP, HDPE, LDPE, PET and other polymers used in production. • Evaluate the impact of changes in raw material suppliers, grades, blends and recycled or alternative materials on product quality and processing performance. • Identify opportunities to reduce material consumption while maintaining product integrity and compliance. • Investigate  material-related production problems in conjunction with Quality and Procurement. • Assist with material trials and the approval of alternative raw materials. • Monitor product weight and material usage against approved specifications and cost targets. F. Continuous Improvement

• Lead and participate in continuous improvement initiatives across the manufacturing operation. • Apply structured problem-solving techniques, including root-cause analysis, 5 Whys and fishbone diagrams. • Implement lean manufacturing principles and waste-reduction initiatives. Develop and monitor key performance indicators (KPIs) relating to production efficiency, scrap, downtime and quality.

• Prepare technical reports and present improvement recommendations to management. • Promote a culture of accountability, process discipline and continuous improvement. G. Training and Technical Support

• Train and support machine operators, setters and production supervisors on correct processing methods and machine settings.
• Develop process documentation, setup sheets and work instructions.
• Provide technical guidance during production start-ups, product changeovers and troubleshooting activities.
• Ensure operators understand the importance of adhering to approved process parameters.
• Share technical knowledge and best practices across production shifts.