Senior Process Engineer

Morgan Advanced Materials is a world leader in advanced materials science and engineering of ceramics, carbon and composites. We operate in a series of well-defined markets where our applications expertise offers our customers a valuable differentiator, engineering high-specification materials, components and sub-assembly parts that solve their challenging technical problems.

The Technical Ceramics business of Morgan Advanced Materials engineers high performance functional and structural ceramic materials, components and sub-assemblies to address customer-specific technical challenges.

The business employs advanced materials science and applications expertise to produce parts that enhance reliability or improve the performance of its customers’ products. Much of what the global business unit makes is used in demanding, harsh or critical environments. Our Technical Ceramics business works in selected segments of the electronics, energy, healthcare, industrial, petrochemicals, security and transport markets, typically in close collaborative customer relationships.

Group Key Figures: Revenue £950m (2021), ~7,500 employees, manufacturing in 30+ countries, and customers in 100+ countries. A UK PLC with head office located in Windsor, Berkshire UK.  Listed on London Stock Exchange; Member of the FTSE 250 Index.

Job Purpose:
The Senior Process Engineer reports directly to the Process Engineering Manager. The Sr. Process Engineer will evaluate a process' efficiency, effectiveness, quality, and safety. They then identify any areas that need to be improved or changed, with the ultimate goal being to make a process efficient and less costly. The Sr. PE also has the responsibility to develop, implement, and manage the manufacturing processes, methods, and equipment designed to ensure continuous production of advanced ceramic and composite materials that meet or exceed our customers’ expectations.  The role is an exciting opportunity to join a global, dynamic, Hi-Tech team, supporting the medical and aerospace industries.  We are the industry leader in development and manufacturer of ceramic to metal seals for both Aerospace and Medical markets.  We help improve the quality of life with our implantable medical components, and we ensure the safety of travelers by developing multiple components for the Aerospace industry. 

Essential Functions:

• Ability to mentor engineers and help the development of a strong team.
• Complete projects from inception to completion including training, project tracking and documentation.
• Develops and implements safe, optimal, cost-effective manufacturing processes, methods, and equipment platforms.
• Performs research, design, and development of manufacturing processes, including production work flow, raw material specifications, mixing, molding, and high temperature baking processes, and equipment specifications.
• Designs and implements improvements to manufacturing processes, methods, and controls.
• Designs, develops, tests, and/or outsources various processes, machinery, and equipment for recommended manufacturing methods.
• Develops manufacturing Drawings, Bills of Materials, Routers, Work Instructions, and Control Plans using manufacturing engineering best practices.
• Provide support in new product development & testing, APQP, PPAP, product and process validation, product audits, drawing & BOM conformance, and projects related to standard work & reduction in process variation.
• Supports the conversion of small-scale processes into commercially viable large-scale operations.
• Coordinates manufacturing launch for new or revised products, processes, and equipment.
• Prepares quotations for labor, tooling, and equipment to support the business unit requirements.
• Performs product/process analysis and implements continuous improvement initiatives for cost reduction, scrap reduction, yield improvements and increased overall equipment efficiency.
• Conducts PFMEAs on manufacturing processes, methods, equipment, and controls.
• Represents process engineering on cross-functional teams. Communicate with engineering, quality and supply chain team to assist in MRB, RMA, material disposition, root-cause analysis, and in preparation and follow-up of corrective action reports.
• Participates in concurrent engineering design reviews.
• Writes and submits Capital Expenditure requests.
• Evaluates and troubleshoots manufacturing, quality and assembly line issues using failure mode effect analysis (FMEA) and other problem solving methods, perform process capacity and capability analysis.
• Assists in training all shop floor associates on manufacturing processes and methods.

Minimum Qualifications and Education Requirements:

• BS. degree in Material Science or Engineering.
• 7-10 years related experience.
• Prior experience working with manufacturing processes that utilize raw material handling, mixing, molding, and high temperature baking equipment (mixers, presses, ovens, etc.) is required.
• Basic understanding of quality management systems in an ISO 9001/AS 9100 is required.
• Knowledge of Kaizen and Lean Manufacturing techniques.
• Experience with developing/documenting procedures is required.
• Materials experience – specific to ceramics.
• This position requires use of Controlled Unclassified Information (CUI) which is subject to the International Traffic in Arms Regulations (ITAR), Export Administration Regulations (EAR), and Nuclear Regulatory Commission (NRC).

• Individual must be a:

  • Citizen of the United States, or
  • Permanent resident alien of the United States, or
  • Protected individual as defined by 8 U.S.C. 1324b(a)(3) as defined by 22CFR120.15

Additional Requirements:

• Quality orientation and high attention to detail.
• Excellent interpersonal and communication skills.
• Experience working with high performance teams.
• Problem analysis and problem resolution skills.
• Must be familiar with Microsoft Office Suite.
• Must be able to clearly present ideas and reports in written and verbal format.
• Must be able to work well with subordinates, peers and superiors in all departments of the Company.
• Must be able to work well with external contacts of the Company.
• Must have good time management, planning and negotiation skills.

Physical Requirements:

• The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.
• Must be capable of sitting and using a computer for extended periods of time throughout the workday
• Must be capable of occasional travel.
• Must have the ability to maneuver the shop floor, administer postings, and general administration throughout the facility.
• Required to talk or hear.
• Required to pass eye tests.
• Required to stand, walk, and sit.
• Required to use finger, handle, feel & reach with hands & arms.
• Frequently lift and/or move up to 10 lbs, and occasionally lift and/or move up to 25 lbs.
• Vision abilities include close vision, color vision, depth perception, and ability to adjust focus.

Morgan Advanced Materials is an EEO/AA/M/W/D/V Employer.

Reasonable accommodations may be made to enable individuals with disabilities to perform essential functions of this job. While performing the duties of this job, the employee is occasionally exposed to moving mechanical parts, fumes, or airborne particles, and toxic caustic chemicals.  The noise level in the work environment is usually moderate.

This job description does not state or imply that all duties to be performed are specifically identified above. Employees are required to follow any other job-related instructions and to perform any other job-related duties requested or instructed by an authorized person of the Company. This document does not create an employment contract, implied or otherwise, other than an “at-will” relationship.