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Product Development Engineer

Reports To: Product Development Team Leader

Employment Type: Full-time Exempt

Welch Overview:

We are experts in converting high-performance fluoropolymer films into intricate three-dimensional shapes using thermoforming and precision heat sealing. Our corporate culture is a true team environment where there is a presence of clear purpose, the strength of real fraternity, and the celebration of individual creativity.

Duties and Responsibilities:

  • In collaboration with cross functional team, contribute to the development and review of process Failure Modes Effects and Analysis (FMEA)
  • Perform Measurement System Analysis (MSA) to certify measurement system’s accuracy, precision and stability
  • Use Hypothesis Testing and ANOVA to examine the performance of manufacturing tooling and/or equipment
  • Conduct Design of Experiments (DOE) to observe the interactions of manufacturing parameters and determine settings to achieve optimal results
  • Create Manufacturing Work Instructions and/or Procedures which must be able to be understood by non-technical Team Members and provide necessary training to created documents
  • Plan, schedule, and supervise Operation and Process Qualification Lots with Technical Service Technicians and Manufacturing Team Members
  • Analyze results of Characterization and Process Qualification Lots using Statistical Process Control principles (Capability Analysis, Control Charts, Scrap Pareto Charts, Cycle and Takt Time comparisons) to asses if developed product and process is capable of achieving the Customer and Welch’s specifications
  • Update Bills of Manufacture (BOMs) based on Qualification results and release through Engineering Change Order (ECO) process
  • As needed, design and implement simple tooling modifications and/or additions to improve product and/or process results, or collaborate with Research and Development Engineers to implement more complex tooling and equipment modifications and/or additions
  • Collaborate with Research and Development Engineers to develop Qualification Protocol that will sufficiently test the capability of a product and process to achieve the Customer and Welch’s specifications
  • Following Welch’s standard procedure, complete tasks required of the Operation and Process Qualification and document results in the Qualification Report
  • Using data-based analysis, provide thoughtful written summaries and conclusions as required in the Qualification Report, which can be understood by both technical and non-technical Team Members.
  • As assigned by Project Managers, complete tasks in the Product Release Checklist.
  • Create presentation summarizing Process Qualification results and present to Team Members and Leadership in Product Release Meeting.
  • Utilize pragmatic, industry standard methodologies (A3, 5-Why, Plan-Do-Check-Act (PDCA)) to provide technical support to released product and process activities including scrap reduction initiatives and corrective actions (CARs/SCARs).
  • Clearly document methodologies, results, and data-based analysis and conclusions that can be understood by technical and non-technical Team Members
  • Other tasks as assigned by the Product Development Team Leader

Qualifications/Requirements

  • Bachelor of Science degree in an Engineering field
  • Degree must be from an institution accredited by the Engineering Accreditation Commission of ABET
  • Mechanical Engineering degree is preferred, but other disciplines will also be considered
  • Minimum of five years’ experience is preferred in a manufacturing facility producing product for a highly regulated industry (medical, automotive, government, etc)
  • Knowledge of materials and equipment used in plastic part fabrication
  • Some knowledge of plastic part fabrication techniques (common forming/sealing methods & equipment), thermoforming is particularly valuable
  • Some knowledge of machine design, simple electrical design, and understanding of common manufacturing practices
  • Familiarity with commonly used engineering systems, methods of analysis, and business tools
  • Statistics familiarity, specifically the principles of capability analysis, design of experiments (DOE), measurement systems analysis (MSA), hypothesis testing, and ANOVA
  • Intermediate computer skills; Microsoft Word, Excel, Powerpoint, etc. with the ability to learn new ones
  • Working knowledge and direct experience using 3D CAD software
  • Solidworks
  • Knowledge of Engineering drawing standards

Skills/Competencies :

  • Attention to details
  • Showing diligence to complete tasks correctly and accurately, scrutinizing your own work as objectively as possible, as well as inviting others to review your work
  • Highly organized in thinking, able to apply logic to questions that others cannot
  • Clarity of thought
  • Logical assessment of problems and/or solutions
  • Ability to learn quickly; new processes, new equipment, and/or new methods and lead others in their learning of the same
  • Knowing when and where to get help or advice when issues become critical or overly complex
  • Ability to multi-task successfully
  • To work well in a fast-paced environment with many potential distractions without losing sight of given priorities
  • Effective communicator
  • Able to be understood by most when creating documents or training others on new processes/equipment
  • Able to work successfully with a variety of people from several functional groups, cultures, and backgrounds

Physical Requirements:

  • Ability to travel for business
  • Air and motor vehicle travel (either in the US or internationally) when required (<5% of time)
  • Able to lift 30 pounds without help of equipment, but using proper lifting techniques
  • Able to ascend/descend ladders, stairs, and crouch/kneel (for short periods) To have sufficient visual acuity (with correction if necessary) to see small parts, part defects, and read computer monitors/documentation
  • Able to work in conditions of high heat and humidity above 90 degrees F for several hours at a time
  • Able to sit for several hours at a time when performing design work or doing data analysis
  • Must have the vision abilities to observe, determine, inspect, estimate and assess information using a computer or physically inspecting tools or machinery
  • Must be able to verify identity and eligibility to work in the United States and to complete the required employment eligibility verification form