Manufacturing Engineer - Plastics Focus bei Gentex Corp

Description

PURPOSE:

The Manufacturing Engineer (Plastics) will lead the development, optimization, and implementation of advanced manufacturing technologies and processes for composite, extrusion, and injection molding applications in aerospace and defense. The engineer will drive new product introductions, support ongoing production, and champion continuous improvement initiatives to enhance safety, quality, productivity, and cost-effectiveness. The position blends hands-on engineering with strategic process development, tooling design, and cross-functional collaboration.

DUTIES / RESPONSIBILITIES (List what the incumbent is required to do): 

New Product Development & Transfer to Production

• Lead transition of ballistic, impact-resistant, and plastic-based systems from design to production
• Collaborate with cross-functional teams to ensure tool development, process readiness, and manufacturability
• Conduct design reviews, calibrations, and pre-production builds

Process Optimization & Troubleshooting

• Analyze and improve legacy processes using Lean and Six Sigma tools
• Lead root cause investigations and implement corrective actions
• Monitor production lines and identify yield improvements using SPC
• Transform batch systems into continuous flow lines and balance operations to Takt Time
• Develop critical parameters for plastic extrusion and injection molding processes
• Evaluate resin formulations and extrusion parameters to meet product specs

Technical Leadership & Innovation

• Research and recommend new manufacturing technologies, including automation and AI
• Lead tooling design, procurement, and fabrication for cost-effective production
• Manage equipment lifecycle and support tooling rework and qualification
• Conduct experimental trials to eliminate scrap and replace obsolete materials
• Support audits and ensure compliance with industry standards

Cross-functional Support

• Provide technical support to manufacturing, purchasing, production control, and quality assurance
• Resolve supplier issues and process problems impacting performance and quality
• Interface across all organizational levels to communicate findings and drive action
• Train employees on new processes and best practices
• Develop Standard Work Instructions, PFMEAs, control plans, and process documentation
• Be able to communicate to all levels of the organization through written or verbal format when it comes to advice on incident investigation, corrective action, collecting, recording, and transcribing data, as well as showing results in various types of reports
• Research and purchase new manufacturing technology
• Schedule flexibility to support critical deadlines may be required 

Requirements

EDUCATION AND/OR PROFESSIONAL LICENSE(s):

Bachelor of Science degree in Plastics Engineering, Materials Engineering, Mechanical or Industrial Engineering, Manufacturing Engineering or equivalent technical degree is required. Advanced Degree Preferred

EXPERIENCE: 

• 2-5 years of experience in manufacturing engineering, preferably in aerospace/defense or high-performance plastics/composites
• Strong background in extrusion, injection molding, composite materials, and secondary operations
• Experience developing manufacturing documentation (MCPs, SWIs, BOMs, Labor Routings)
• Familiarity with optics resin systems, dye packages, or colorants is a plus

KNOWLEDGE, SKILLS, AND ABILITIES:

• Deep understanding of composite and plastic manufacturing processes, tooling, and design for manufacturability
• Proficient in Lean, Six Sigma, DMAIC, Kaizen; certification preferred
• Skilled in PFMEA, SPC, GD&T, root cause analysis, and process capability studies
• SolidWorks (3D modeling), Microsoft Office Suite, Visio, Project, and Minitab proficiency
• Strong communication and organizational skills; able to manage multiple priorities
• Familiarity with AS9100 standards and NPI stage gates
• Ability to lead design reviews, experimental trials, and process qualifications
• Self-starter with a passion for driving change and solving complex manufacturing challenges

POSITION SUPERVISES:

Position will be primarily one of an individual contributor. May be required to supervise and coordinate activities with technicians or lab personnel and coordinate with engineers but will not be directly responsible for reporting/evaluating others. Candidate needs to take direction and work independently with minimal supervision.

CONTACT WITH OTHERS:

This position requires contact and interaction with a multitude of technical disciplines within GENTEX Corporation, not only within the Carbondale facility, but with “sister” plants throughout the United States.

This position will also require interaction with GENTEX suppliers and occasionally with the customer.

PHYSICAL/MENTAL/COMMUNICATION REQUIREMENTS:

Employee is occasionally required to stand; walk; sit; use hands to finger, handle, or feel objects, tools, or controls; reach with hands and arms; climb stairs; balance; stoop, kneel, crouch, or crawl; talk or hear; and taste or smell. The employee may lift and/or move up to 50 lbs. Specific vision abilities required by the job may include close vision, distance vision, color vision, peripheral vision, depth perception, and the ability to adjust focus. The individual must have a high level of comprehension, and a high level of general, verbal, written, and numerical intelligence.

WORK ENVIRONMENT:

Works majority of the day in a climate-controlled environment, with the exception of, or otherwise specified, performing work in the warehouse or manufacturing areas which are subject to changes in temperature and/or noise.

TRAVEL:

Limited travel required 

LOCATION:

Gentex’s Carbondale facility is located in Northeastern Pennsylvania in Lackawanna County. Carbondale, PA is about twenty miles north of Scranton, PA, 50 miles south of Binghamton, NY, and about 125 miles from New York City and Philadelphia. The area hosts numerous nearby state parks, nature preserves and local colleges and universities, including The University of Scranton and Marywood University. Northeast Pennsylvania is a beautiful area and offers an excellent cost of living. It is a great place to work, recreate, meet people, raise a family and live!

Gentex Corporation is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard for any applicable state or federal protected class. Gentex is an E-Verify Participant. Pre-employment drug/alcohol/background screening is required.