Material Process Engineer

Job Description

Key Responsibilities

1. 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. Utilize Design of Experiments (DOE) methodologies to establish robust process windows and improve process uniformity and repeatability.  Additional work will be to implement the most advanced material processing technologies in support of growth programs.

2. Technical Support & Production Troubleshooting

Provide technical support to production teams for film operations. Diagnose and resolve process-related issues such as shrinkage, warpage, adhesion loss, surface defects, oxidation, or inconsistent material behavior. Implement corrective and preventive actions to minimize waste, reduce downtime, and improve overall equipment effectiveness (OEE).

3. Equipment Oversight & Maintenance Coordination

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.

4. Quality Control & Material Characterization

Conduct comprehensive material characterization including dimensional stability analysis, surface quality inspection, adhesion testing, optical property evaluation (e.g., clarity, haze, transmittance), and mechanical property testing (e.g., tensile strength, elongation). Establish and implement quality control procedures to ensure annealed film materials meet product specifications and performance requirements. Utilize statistical process control (SPC) and maintain process capability indices (CPK) to monitor and control critical parameters.

5. Documentation & Standardization

Develop and maintain comprehensive technical documentation including process flowcharts, control plans, PFMEA (Process Failure Mode Effects Analysis), 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.

6. 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.

All Job Posting Locations

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.