Job Description

Key Responsibilities

New Process Development for Film Materials

• Develop, design, and implement new processes specifically for thin‑film materials (e.g., polymer films, coated substrates, flexible composites).
• Priority will be on implementing annealing processes including optimizing parameters such as temperature profile, soaking time, heating/cooling rates, and atmosphere conditions to achieve desired material properties, dimensional stability, and surface quality.
• Additional work will be to implement the most advanced material processing technologies in support of growth programs.

Mechanical Design & Reliability Engineering

• Design, develop, and integrate custom automation equipment (fixtures, end-effectors, feed systems, and complete assembly lines).
• Perform structural and kinematic analysis to ensure system rigidity, accuracy, and speed.
• Select and size appropriate mechanical components (servo motors, pneumatic actuators, linear guides, sensors).
• Apply design reliability tools including:
  • DFMEA (Design Failure Mode and Effects Analysis) to proactively identify and mitigate design risks.
  • GD&T (Geometric Dimensioning and Tolerancing) and tolerance stack‑up analysis to ensure part interchangeability and assembly feasibility.
  • Simulation/CAE verification (structural, thermal, or motion) to validate design performance before prototyping.

Process Optimization & Efficiency Engineering

• Conduct MTM (Methods-Time Measurement) analysis to establish standard times and improve manual/automated work sequences.
• Perform CT (Cycle Time) analysis to optimize throughput, identify bottlenecks, and drive OEE (Overall Equipment Effectiveness) improvements.
• Apply DOE (Design of Experiments) methodology to systematically identify critical process parameters and optimize equipment settings for yield improvement (complementary to the DOE work in Item 1, with a broader focus on production efficiency).
• Integrate Ergonomics principles into equipment design to ensure operator safety, reduce physical strain, and enhance usability (reach, force, and posture analysis).

Quality System, Documentation & Standardization

• Work closely with Production, Quality, and Material R&D teams to troubleshoot process deviations and implement corrective mechanical modifications.
• Develop and maintain comprehensive technical documentation including:
  • Process flowcharts
  • Control Plans
  • PFMEA (Process Failure Mode and Effects Analysis) for process risk assessment
  • Work instructions and Standard Operating Procedures (SOPs)
• Establish process parameters and maintain traceability records for production and audit compliance with ISO9001 and other applicable quality management standards.
• Apply additional quality system tools to ensure process stability and defect prevention:
  • MSA (Measurement System Analysis) to validate gauge capability.
  • SPC (Statistical Process Control) and CPK analysis to monitor and control process capability.
  • 8D problem‑solving methodology and Root Cause Analysis for systematic issue resolution.
• Create comprehensive validation protocols (IQ/OQ/PQ) and technical documentation as required.

Process Understanding & DFM/DFA Principles

• Deeply understand the process mechanism of production lines—not just "the machine works" but "why the machine works with this specific material." Ensure that mechanical design is inherently matched to product process requirements (adhesion properties, thermal sensitivity, material flow, etc.).
• Implement DFM (Design for Manufacturing) and DFA (Design for Assembly) principles from concept stage, ensuring that designs are optimized for ease of fabrication, assembly, maintenance, and cost‑effective production.

Project Execution & Cross‑functional Leadership

• Manage end‑to‑end project execution, including:
  • Cost estimation and budgeting for automation equipment.
  • Prototype debugging and validation—from lab setup to production release.
  • Cross‑functional coordination across engineering, production, quality, and supply chain.
  • Risk prediction and mitigation-anticipating technical, schedule, and supply‑chain risks before they become issues.

Equipment Commissioning, Operation & Maintenance

• Oversee the initial operation, calibration, and preventive maintenance of new process equipment including roll‑to‑roll ovens, convection furnaces, infrared heating systems, and batch ovens.
• Collaborate with maintenance teams to ensure process stability, equipment reliability, and minimal unplanned downtime.
• Support new equipment installation, commissioning, and capability qualification to bring new lines into production smoothly and on schedule.

Continuous Improvement & Failure Analysis

• Lead continuous improvement initiatives to enhance annealing efficiency, reduce cycle time, lower energy consumption, and minimize material waste.
• Perform root cause analysis for non-conformances and material failures using systematic methodologies such as Cause Map, 8D, or DMAIC (Define‑Measure‑Analyze‑Improve‑Control).
• Implement preventive actions and share lessons learned across the organization to drive a culture of continuous learning and process excellence.

Other tasks assigned by the superior.

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Remote Type

EEO Statement

Boyd Corp is an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive environment for all employees.