Process Engineer

Location: Montgomeryville, United States of America

Thales people architect identity management and data protection solutions at the heart of digital security. Business and governments rely on us to bring trust to the billons of digital interactions they have with people. Our technologies and services help banks exchange funds, people cross borders, energy become smarter and much more. More than 30,000 organizations already rely on us to verify the identities of people and things, grant access to digital services, analyze vast quantities of information and encrypt data to make the connected world more secure.

The Process Engineer is a member of the Engineering team who will be responsible for coordinating Process Engineering projects of all types and supporting equipment improvements as necessary in the manufacturing industry for identity documents and financial transaction cards.  This position will be responsible for the development of risk assessment, comprehensive qualification tests, and robust industrialization plans related to the introduction of any new product/material into the manufacturing plant or subsequent processes.  The Process Engineer will also be responsible for conducting equipment and process capability studies identified as needed by management or identified in any industrialization plan. They will be responsible for  developing and implementing equipment/process parameters and controls that facilitate an excellent  production environment by ensuring  equipment and processes are statistically capable and in control.  The Process Engineer will troubleshoot manufacturing material, method, equipment  and product issues by interacting with operation, maintenance and quality teams as well as engineering peers.

• Coordinating, implementing, and qualifying process-related engineering changes
• Implementing lean manufacturing techniques into production cells
• Preparation of  change management documentation around product/material changes or new introductions
• Assisting in new-product qualifications and introductions
• Coordinating appropriate maintenance support for projects as necessary
• Supporting manufacturing teams as required
• Monitoring and continuously improving manufacturing quality and efficiency (e.g. reduce cycle time, yield improvement, process controls, etc.)
• Assisting maintenance technicians on projects that require a high level of engineering analysis
• Coordinate inter-company technology and equipment transfers
• Support production automation by modifying or creating tools to eliminate the possibility of human error

• B.S. or equivalent in Mechanical, Electrical, Materials, or Manufacturing/Industrial Engineering
• 3-7 years of Process Engineering experience in a manufacturing facility
• Strong written and inter-personal communication skills 
• Demonstrated ability to effectively interact with employees in a culturally diverse environment
• Experiential knowledge of Lean Manufacturing concepts is essential (SPC, DMAIC, Kaizen, VSM, Kanban, TPM, 5S, Fishbone, FMEA, etc.)
• Desire and ability to collect, analyze and interpret operating data and use it drive improvement
• A high level of competence with Microsoft Windows PC and Microsoft Suite (Excel, Word, Project, Outlook, and PowerPoint) required
• Proven decision making and analytical thinking capability
• Drive root cause analysis and corrective actions for non-conforming processes
• Act as interface with central engineering teams on machine and technology transfers
• Willingness to develop new methods and processes
• Aptitude for and interest in new technologies
• Must be able to perform essential functions of this position with or without a reasonable accommodation

• Equipment knowledge and experience  in plastic card manufacturing a plus
• 1+ year of Lean Manufacturing experience preferred
• Experience with CAD and statistical software packages preferred
• Experience working directly with PLC’s and PLC
• Experience with servo controllers and servo controller logic, pneumatic and hydraulic systems
• Thorough knowledge of electrical/electronic components and equipment including the use of special instruments for diagnostic purposes. Experience with controls and control systems
• Experience with 3D printed parts a plus
• Experience creating reports with databases and tools like PowerBI a plus
• Interest in and understanding of AI tools and Vision Inspection systems a big plus
• Experience and interest in designing and building automated product handling systems incorporating robots, cobots, AGV’s and machine vision

Part office position, with time spent at desk and computer and significant time spent on production floor where employee may be subject to loud manufacturing noises and chemical odors.

Schedule: 9-5, M-F

Physical Environment: Office and production floor

Travel: 0-5%

This position will require successfully completing a post-offer background check. Qualified candidates with (a) criminal history will be considered and are not automatically disqualified, consistent with federal law, state law, and local ordinances.

Successful applicant must comply with federal contractor vaccine mandate requirements.

Thales champions inclusion and we believe diversity strengthens the fabric of our culture. We are an equal opportunity/affirmative action employer. All qualified applicants will receive consideration for employment without regard to sex, gender identity, sexual orientation, race, color, religion, national origin, disability, protected Veteran status, age, or any other characteristic protected by law

If you need an accommodation or assistance in order to apply for a position with Thales, please contact us at talentacquisition@us.thalesgroup.com.