Senior Process Engineer

Job Summary:

Core Duties

Process Development and Optimization

• Develop, refine, and optimize TPU extrusion processes in collaboration with existing organizations in internal lab-based development
• Establish and maintain process parameters to ensure consistent product quality
• Lead root-cause analysis and corrective actions for process deviations, scrap, and downtime.
• Implement continuous improvement initiatives using Lean, Six Sigma, or similar methodologies.

Technical Leadership, Support, and Troubleshooting

• Provide day-to-day technical support to production teams for extrusion lines.
• Troubleshoot issues related to melt temperature, die design, screw configuration, cooling, and downstream equipment.
• Partner with R&D to scale up new TPU formulations and product designs from lab to production.
• Conduct extrusion trials, document results, and establish robust manufacturing processes.
• Collaborate with research and development teams as technologies transition to pilot & scale-up environments to ensure successful commercialization.

Quality, Safety, and Compliance Leadership

• Develop and maintain process documentation, including work instructions, control plans, and standard operating procedures.
• Work closely with Quality to ensure compliance with customer specifications and industry standards.
• Analyze process data to identify trends and drive quality improvements.

Data Performance, Analytics, and Strategic Improvement

• Monitor key process indicators (KPIs) such as yield, scrap rate, cycle time, and line efficiency.
• Use statistical tools to evaluate process capability and stability.
• Recommend and implement process automation or digital monitoring enhancements.

Basic Qualifications

• Bachelor’s degree in Chemical, Polymer, Mechanical, Materials Engineering, or a related field.
• 6+ years of progressive experience in process engineering, with strong exposure to polymer films, coatings, or similar manufacturing environments.
• Deep hands-on expertise with manufacturing equipment, including leading equipment optimization, upgrades, and reliability improvements.
• Proven ability to lead complex troubleshooting efforts, applying data-driven methodologies to resolve issues and optimize critical process parameters.
• Advanced proficiency in continuous improvement and problem-solving frameworks with demonstrated project leadership and measurable results.
• Strong analytical capabilities with experience in statistical analysis, process capability, and hypothesis-driven problem solving.
• Demonstrated leadership in cross-functional collaboration, with the ability to influence stakeholders and drive alignment across production, quality, and R&D teams.
• Experience managing multiple high-impact projects simultaneously in fast-paced manufacturing environments, with strong prioritization and execution skills.
• Strategic mindset with a strong attention to detail, focused on long-term process sustainability, scalability, and cost optimization.
• Proven track record of mentoring junior engineers and contributing to team development and technical growth.
• Willingness and ability to travel 25-50% to support multi-site operations, equipment vendors, and scale-up activities.

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