{"id":1430632,"url":"https://alion.io/job/xpel-senior-process-engineer","title":"Senior Process Engineer","company":{"id":1852724,"name":"XPEL","domain":"xpel.com","url":"https://alion.io/company/xpel-com","size_band":"501-1000","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"Workday","truth_index":{"grade":"B","score":75,"open_postings":17,"ghost_share":0,"stale_share":1,"repost_share":0,"time_to_fill_p50_days":30,"computed_at":"2026-10-22T06:10:10Z"}},"role":"Industrial Engineering","role_family":"Industrial Engineering","seniority":"senior","employment_type":"full_time","work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["San Antonio, United States"],"countries":["US"],"hiring_countries":[],"hiring_countries_total":0,"salary":null,"salary_estimate":{"min_usd":104000,"max_usd":197000,"period":"year","method":"role_seniority_country_remote_cell","sample_n":5966},"experience_years_min":6,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[{"name":"TPU","optional":false}],"status":"live","first_seen_at":"2026-04-06T00:00:00Z","employer_posted_date":"2026-04-06","last_verified_at":"2026-10-22T01:19:50Z","board_verified":true,"closed_at":null,"days_open":200,"trust":{"level":"stale","repost_count":0,"flags":["stale"],"days_open":199},"description":"Job Summary:\nWe are seeking a highly skilled Process Engineer with direct experience in thermoplastic polyurethane (TPU) extrusion for Paint Protection Film (PPF) applications. This role is responsible for working with organizations developing, optimizing, and scaling extrusion processes that produce optical-grade TPU films with exceptional clarity, mechanical durability, and surface performance. The ideal candidate understands the unique challenges of PPF manufacturing, including optical defects, gel control, surface uniformity, and tight thickness tolerances.Core Duties\nProcess Development and Optimization\nDevelop, refine, and optimize TPU extrusion processes in collaboration with existing organizations in internal lab-based development\nEstablish and maintain process parameters to ensure consistent product quality\nLead root-cause analysis and corrective actions for process deviations, scrap, and downtime.\nImplement continuous improvement initiatives using Lean, Six Sigma, or similar methodologies.\nTechnical Leadership, Support, and Troubleshooting\nProvide day-to-day technical support to production teams for extrusion lines.\nTroubleshoot issues related to melt temperature, die design, screw configuration, cooling, and downstream equipment.\nPartner with R&D to scale up new TPU formulations and product designs from lab to production.\nConduct extrusion trials, document results, and establish robust manufacturing processes.\nCollaborate with research and development teams as technologies transition to pilot & scale-up environments to ensure successful commercialization.\nQuality, Safety, and Compliance Leadership\nDevelop and maintain process documentation, including work instructions, control plans, and standard operating procedures.\nWork closely with Quality to ensure compliance with customer specifications and industry standards.\nAnalyze process data to identify trends and drive quality improvements.\nData Performance, Analytics, and Strategic Improvement\nMonitor key process indicators (KPIs) such as yield, scrap rate, cycle time, and line efficiency.\nUse statistical tools to evaluate process capability and stability.\nRecommend and implement process automation or digital monitoring enhancements.\nBasic Qualifications\nBachelor’s degree in Chemical, Polymer, Mechanical, Materials Engineering, or a related field.\n6+ years of progressive experience in process engineering, with strong exposure to polymer films, coatings, or similar manufacturing environments.\nDeep hands-on expertise with manufacturing equipment, including leading equipment optimization, upgrades, and reliability improvements.\nProven ability to lead complex troubleshooting efforts, applying data-driven methodologies to resolve issues and optimize critical process parameters.\nAdvanced proficiency in continuous improvement and problem-solving frameworks with demonstrated project leadership and measurable results.\nStrong analytical capabilities with experience in statistical analysis, process capability, and hypothesis-driven problem solving.\nDemonstrated leadership in cross-functional collaboration, with the ability to influence stakeholders and drive alignment across production, quality, and R&D teams.\nExperience managing multiple high-impact projects simultaneously in fast-paced manufacturing environments, with strong prioritization and execution skills.\nStrategic mindset with a strong attention to detail, focused on long-term process sustainability, scalability, and cost optimization.\nProven track record of mentoring junior engineers and contributing to team development and technical growth.\nWillingness and ability to travel 25-50% to support multi-site operations, equipment vendors, and scale-up activities.\nXPEL is an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive environment for all employees.","description_format":"text","description_chars":3869,"description_truncated":false,"requirements":{"experience_years_min":6,"management_years_min":null,"team_size_min":null,"manages_managers":false,"education":{"level":"bachelor","optional":false},"security_clearance":false,"languages":[]},"benefits":[],"hiring_locations":[],"hiring_excludes":[],"relocation_offered":false,"industries":[],"lifecycle":[{"event":"open","at":"2026-09-29T01:18:56Z"}],"visa":[{"country":"US","licensed_sponsor":true,"evidence":"H-1B filings in 12 months: 4","filings_12m":4,"filings_prev_12m":1,"green_card_filings_12m":0,"median_offered_wage_usd":122500,"route":null,"cap_exempt":false,"checked_at":"2026-10-15T11:24:14+00:00","sources":["US Department of Labor: LCA disclosure data (H-1B, H-1B1, E-3)","US Department of Labor: PERM disclosure data (green cards)"],"filings_for_role_12m":0}],"liveness":{"score":7,"band":"cold","label":"Long shot","p_open":1,"p_active":0.264,"p_room":0.28,"age_days":199,"expected_fill_days":30,"reasons":["conf:4","stale_co","win:tail","crowd:"],"computed_at":"2026-10-22T06:10:10Z"},"pay":null,"html_url":"https://alion.io/job/xpel-senior-process-engineer","json_url":"https://alion.io/job/xpel-senior-process-engineer.json","meta":{"generated_at":"2026-10-23T02:42:10Z","cache_seconds":300,"methodology":"https://alion.io/methodology","terms":"https://alion.io/terms","contact":"https://alion.io/contact","api":"https://alion.io/developers","about":"Alion is a live layer of people, companies and AI agents: who they are, whether they are real and active right now, what they do and how to work with them, readable by people and by agents and paid per call.","catalog":"https://alion.io/catalog.json","usage":{"tier":"crawler_verified","counted_by":"address","units_charged":1,"used_today":4449,"day_limit":null,"remaining_today":null,"minute_limit":300,"resets_at":"2026-10-24T00:00:00Z"}},"offers":[{"id":"company.slices","title":"One company in depth, by slice","status":"live","price":{"credits":0.02,"usd":0.002,"plus_per_slice":{"credits":0.05,"usd":0.005}},"unit":"per company, plus each slice with data","note":"the employer in depth","call":{"mcp_tool":"get_company","arguments":{"id":1852724},"rest":"https://alion.io/mcp/rest/get_company?id=1852724"},"human":"https://alion.io/catalog?offer=company.slices&for=job%2Fxpel-senior-process-engineer"},{"id":"market.stats","title":"A market slice: pay, demand and time to fill","status":"live","price":{"credits":1,"usd":0.1},"unit":"per slice","note":"pay, demand and time to fill for this role and place","call":{"mcp_tool":"market_stats"},"human":"https://alion.io/catalog?offer=market.stats&for=job%2Fxpel-senior-process-engineer"},{"id":"job.search","title":"Open jobs by role, technology, place, pay and visa","status":"live","price":{"credits":0.02,"usd":0.002},"unit":"per posting in a list","note":"similar open postings","call":{"mcp_tool":"search_jobs"},"human":"https://alion.io/catalog?offer=job.search&for=job%2Fxpel-senior-process-engineer"},{"id":"company.verify","title":"Is this company real and active right now","status":"pilot","price":null,"unit":"per company","request":{"url":"https://alion.io/catalog/request","method":"POST","body":"{\"offer\": \"company.verify\", \"for\": \"job/xpel-senior-process-engineer\", \"note\": \"what you need it for\"}"},"human":"https://alion.io/catalog?offer=company.verify&for=job%2Fxpel-senior-process-engineer"}]}