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Process Improvement Engineer: Support Operations – Plastics Processing (Off-Shift Support)

Louisville, KY, United States  |  Engineering  |  ID: REQ-13563


Job Location

USA, Louisville, KY

Job Posting Title

Process Improvement Engineer: Support Operations – Plastics Processing (Off-Shift Support)

The Challenge

Role Summary/Purpose:
Manages equipment and process effectiveness within the AP-5 Plastics Processing. Troubleshoots process issues and drives operational improvements, through effective problem solving and corrective action implementation, to continuously improve safety, quality, delivery, cost & morale.

What you will Do

Essential Responsibilities:          


  • Own the improvement all equipment and tooling in the AP-5 Plastics Processing Areas.
  • Serve as the primary troubleshooting resource for the process in the plant. Consult with maintenance staff on equipment repair.
  • Monitor and work to improve Overall Equipment Efficiency (OEE) and Total Productive Maintenance (TPM) in the area.
  • Recommend equipment and tooling for existing process; consult and sign-off on new purchases when applicable.
  • Audit Preventative Maintenance (PMs) plans to ensure relevance, compliance and maximize equipment uptime.
  • Consult with maintenance staff on the maintenance action item list and/or priorities for the area.
  • Manage and maintain special tools for the area (i.e. ensure spare tools are in crib, tool drawings in place, facilities hand-off).


  • Ensure Manufacturing Control Plan (MCP) is executed and adhered to within production area.
  • Adjust, monitor and document technical processes (extrusion, thermoforming, stamping, molding, foaming, etc.), including deviations, MCI, MCP via BCR process.
  • Monitor process, data & reports on a daily basis and drive the resolution or escalation for any defect.
  • Act as a resource to Controlmen and Area Business Leaders (ABLs) in the creation of Standard work.
  • Work cross-functionally with multiple stakeholders to quickly address and solve production line issues to improve OEE, Scrap, and Yield metrics. (i.e. Controlmen, ABL, QSE, QIE).


  • Engage in and lead problem-solving for fabrication areas. Lead root cause identification of problems, implement appropriate counter measures, and share across as best practice.
  • Live, promote and teach the Appliance Performance System (APS) philosophy and lead continuous improvement.
  • Continuously identify and work to reduce waste in the area.
  • Work cross-functionally with Team Leaders, Business Leaders and Lean resources on short term and long term improvement initiatives.
  • Implement work methods, and develop workstation aids to assist in operator job performance.
  • Work with PIE’s, Controlmen and ABLs on Standard Work and Job Instruction creation.
  • Assist ABLs to ensure 5S tools are in place for the area (i.e. shadow boards)


  • Support ABLs by identifying and implementing safety-related corrective actions and improvements for the area.
  • Assist with action item completion for the area's safety action item list, including corrective actions from near misses, accident reports & ergo assessments.


  • Coordinate with AME on equipment purchases & qualification.
  • Interact with Design Engineers/Technology organization on model changes for manufacturing line set up.
  • Review product prototypes and concepts for manufacturability.
  • Provide feedback to the NPI team on capacity, impact on process stability/sustainability.
  • Participate in product test runoffs.
  • Interface with vendors and OEM suppliers, along with Facilities Engineer, to learn maintenance requirements and equipment troubleshooting. Distribute information and knowledge.
  • Update manufacturing control documents, floor & workstation layouts. Work with PIE, Controlmen and ABLs on Standard Work and Job Instruction creation.

What you need to Succeed

Minimum Qualifications:

  • Minimum of Bachelor’s Degree with technical degree required (or equivalent experience.)
  • Minimum of 7 years’ experience in Manufacturing Engineering/Operations/Quality support roles.
  • Minimum of 5 years with Plastics Processing preferably Extrusion and Thermoforming.
  • Minimum of 3 years or more leadership experience in manufacturing operations, preferably unionized operations.

Position Requirements:

  • Demonstrated experience in troubleshooting high volume manufacturing equipment.
  • Proven ability to influence and drive change.
  • Experience in high volume manufacturing environment.
  • Experience in material flow.
  • Solid verbal/written communication skills coupled with strong interpersonal skills.
  • Advanced computer skills - high proficiency in Microsoft products (especially Excel) and ability to grasp new systems quickly.
  • Strong project management and analytical/problem solving skills with demonstrated ability to scope and analyze cross-functional problems to generate/implement solutions.
  • Must have experience applying time studies and/or standard work.
  • Ability to adapt to and juggle changing and competing priorities.
  • This position is a second shift role.  Early and/or late hours often required to work around the manufacturing schedule / timing.
  • Ability to work collaboratively in a cross-functional team environment with both hourly and salary personnel to meet the needs of operators, the program and the business.
  • High initiative, self-starter, proactive, dedicated, results oriented, a team player.

    Preferred Characteristics:

    • Experience in Controls, PMs, mechanical, hydraulic, pneumatics and welding techniques.
    • Knowledge of Appliances manufacturing processes.
    • Experience and training in lean manufacturing practices.
    • Program Management skills.
    • Experience with TPM
    • Six Sigma Black Belt certification.
    • Quality Leadership experience.

    Working Conditions:

    • Working conditions are normal for both an office and manufacturing environment.
    • Work may involve lifting of materials and product up to 25 pounds.
    • Working in the manufacturing environment requires the use of safety equipment to include but not limited to: safety glasses, hearing protection, gloves, work shoes/boots.
    • Work may require occasional weekend and/or evening work.
    • Travel may be required for domestic and/or international travel to other sites/plants, etc.

    GE Appliances is an Equal Opportunity Employer.  Employment decisions are made without regard to race, color, religion, national or ethnic origin, sex, sexual orientation, gender identity or expression, age, disability, protected veteran status or other characteristics protected by law.



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