Process Engineer

Corrugator process control

• Set and maintain standard operating parameters per flute (A, B, C, E, BC) and board grade: steam pressure, preheater wrap, glue gap, starch viscosity and solids, and bridge and double-backer speeds.
• Troubleshoot board defects such as warp, delamination, washboarding, high-low flutes, blisters and crushed flutes.
• Manage the starch kitchen recipe and its quality checks (viscosity, gel point, solids) with QC.
• Improve order changeovers and trim optimization with Planning to reduce side trim and roll-change waste.

Converting process control

• Standardize settings for printer-slotters, die-cutters and folder-gluers, including impression, anilox and ink, slotting and creasing, and glue application.
• Reduce make-ready and changeover times through SMED and pre-staging of plates, dies and ink.
• Resolve converting defects such as print misregister, color variation, cracked scores, gap and fishtail on glued joints, and box squareness.

Waste, yield and efficiency

• Measure and report waste by line, shift, defect type and customer, from paper roll to finished box.
• Track OEE, run speed, downtime and changeover time for every line, and lead root-cause analysis on major losses.
• Run cost-reduction projects on paper consumption, starch usage, ink usage, steam and electricity.
• Evaluate cheaper or lighter paper combinations that still meet customer ECT, BCT and burst requirements.

Quality and customer requirements

• Work with QA on board and box tests (ECT, BCT, burst, FCT, moisture, caliper, Cobb) and link test failures to process causes.
• Lead corrective and preventive actions (CAPA) on customer complaints, using 8D, 5 Whys or fishbone analysis.
• Support ISO 9001, FSC and food-safety or customer audits on process controls and records.

New products and projects

• Run trials for new board grades, paper suppliers, inks and box designs before mass production.
• Support capacity planning, new machine installation and commissioning, and line layout changes.
• Coordinate with Maintenance on preventive maintenance priorities that affect quality and uptime.

Standards and training

• Write and update SOPs, work instructions, set-up sheets and defect catalogues for each machine.
• Train operators and supervisors on standard settings, defect recognition and first-response troubleshooting.
• Promote 5S, safety and lean practices on the production floor.