Process Engineer

Overview

Morgan Advanced Materials is a world leader in advanced materials science and engineering of ceramics, carbon and composites. We operate in a series of well-defined markets where our applications expertise offers our customers a valuable differentiator, engineering high-specification materials, components and sub-assembly parts that solve their challenging technical problems.

The Technical Ceramics business of Morgan Advanced Materials engineers high performance functional and structural ceramic materials, components and sub-assemblies to address customer-specific technical challenges.

The business employs advanced materials science and applications expertise to produce parts that enhance reliability or improve the performance of its customers’ products. Much of what the global business unit makes is used in demanding, harsh or critical environments. Our Technical Ceramics business works in selected segments of the electronics, energy, healthcare, industrial, petrochemicals, security and transport markets, typically in close collaborative customer relationships.

Group Key Figures: Revenue £950m (2021), ~7,500 employees, manufacturing in 30 countries, and customers in 100 countries. A UK PLC with head office located in Windsor, Berkshire UK.  Listed on London Stock Exchange; Member of the FTSE 250 Index.

Responsibilities

The Process Engineering role is an important position reporting directly to our Site Manager, with responsibility to implement, manage, and improve manufacturing processes, methods, and equipment to ensure continuous production of advanced ceramic and composite products to meet or exceed our customers’ expectations. This role is an exciting opportunity to join a global, dynamic, diverse, Hi-Tech team, directly supporting semiconductor, aerospace, defense, energy and medical industries.

Essential Functions:

• Develop and implement safe, optimal, cost-effective manufacturing processes, methods, and equipment platforms, working closely with engineering, quality, production, and sales teams.
• Application engineering of manufacturing processes including smooth flow production for lean manufacturing in areas of mixing, forming, high temperature firing, metallization, and machining processes.
• Designs and implements improvements to manufacturing processes, methods, and controls.
• Designs, develops, tests, and/or outsources various processes, machinery, and equipment for recommended manufacturing methods.
• Develops manufacturing drawings, bills of material, routers, Work Instructions, and Control Plans using manufacturing engineering best practices.
• Provide support in new product development & testing, APQP, PPAP, product and process validation, product audits, drawing & BOM conformance, and projects related to standard work & reduction in process variation.
• Supports the conversion of small-scale processes into commercially viable large-scale operations.
• Coordinates manufacturing launch for new or revised products, processes, and equipment.
• Prepares quotations for labor, tooling, and equipment to support the business unit requirements.
• Performs product/process analysis and implements continuous improvement initiatives for cost reduction, scrap reduction, yield improvements and increased overall equipment efficiency.
• Represents process engineering on cross-functional teams. Communicates within engineering, quality, and supply chain teams to assist in MRB, RMA, material disposition, root-cause analysis, and in preparation and follow-up of corrective action reports.
• Writes and submits Capital Expenditure requests for area of responsibility.
• Evaluates and troubleshoots manufacturing, quality and assembly line issues using failure mode effect analysis (FMEA) and other problem-solving methods, perform process capacity and capability analysis.
• Assists in training shop floor team members on manufacturing processes and methods.
• Assumes responsibility for the safety and environmental issues associated with the manufacturing processes and equipment.
• Conduct all tasks in a safe and efficient manner complying with all local, state, and federal EHS regulations and with Morgan Hayward, CA EHS Guidelines. Guidelines include but not limited to participation in required EHS training and use of proper PPE. Employees are responsible for reporting hazardous conditions and job-related injuries or illnesses to their supervisor.
• Other duties as assigned.

Minimum Qualifications and Education Requirements

• B.S. degree in Ceramic Engineering, Material Science, or other engineering degree with experience in materials manufacturing
• Prior experience working with manufacturing processes that utilize raw material handling, mixing, milling, forming, and high temperature firing equipment
• Experience with machining processes is a plus
• Basic understanding of quality management systems in an ISO 9001/AS 9100 environment
• Knowledge of Kaizen and Lean Manufacturing techniques is a plus
• Effective oral, written, and interpersonal communication skills
• Proficient in Microsoft Word and Excel

Individual must be a: 

• Citizen of the United States, or 
• Permanent resident alien of the United States, or 
• Protected individual as defined by 8 U.S.C. 1324b(a)(3) as defined by 22CFR120.15

Qualifications

Morgan Advanced Materials is an EEO/AA/M/W/D/V Employer

Reasonable accommodations may be made to enable individuals with disabilities to perform essential functions of this job. While performing the duties of this job, the employee is occasionally exposed to moving mechanical parts, fumes, or airborne particles, and toxic caustic chemicals.  The noise level in the work environment is usually moderate.