Process Engineer at GEICO in Kalkaska, MI

Job Description:

COMPANY OVERVIEW

Illinois Tool Works Inc. (ITW) is a Fortune 200 global manufacturer with over $15.9B in revenue, known for its decentralized structure, customer-focused innovation, and operational excellence. Founded in 1912, ITW operates across 50+ countries, delivering specialized solutions through its unique 80/20 business model.

Division Overview – ITW Specialty Films

ITW Specialty Films produces high-performance coated and metallized films for industries including Financial Cards, Secure ID, Medical Packaging, and Holographics. With eight facilities across North America and Europe, we combine deep technical expertise with agile manufacturing to meet complex customer needs.

ITW offers a comprehensive and competitive benefits package including medical plan options with FSA and HSA plans, dental, prescription drug, vision, 401(k) with a company match, life insurance, wellness programs, employee discounts, 12 paid holidays per year, vacation and sick time starting in year of hire, and a corporate matching gift program for charitable donations! More information can be found here: https://myitwhr.com/

ESSENTIAL DUTIES AND RESPONSIBILITIES

Process & Technical Excellence

• Lead the setup, optimization, and ongoing improvement of mixing, coating, and converting processes by establishing and maintaining standard operating conditions and process windows.
• Develop and maintain PFMEAs, Control Plans, Process Flow Diagrams, operation sheets, and other manufacturing documentation; ensure change management processes remain current and effective.
• Utilize structured problem-solving methodologies to identify root causes, reduce process variation, and minimize scrap.
• Conduct equipment capability assessments and drive performance improvements for mixers, mills, gravure cylinders, coating systems, and web-handling equipment.

Continuous Improvement & Data Analytics

• Analyze key performance indicators including OEE, downtime, scrap, and material variance to identify improvement opportunities and lead Lean manufacturing initiatives that enhance yield, throughput, and cost performance.
• Develop, maintain, and communicate operational dashboards and performance metrics; sustain improvements through standardized work, visual management, and layered process audits.
• Support capital investment decisions by providing data-driven analysis and return-on-investment justifications.

New Product / Material Scale-Up & Change Management

• Plan, coordinate, and execute production trials for new film structures, coatings, inks, resins, and material changes; document results and incorporate learnings into standard operating conditions.
• Partner with R&D, Quality, and Supply Chain teams to validate product performance, conduct DOE and process capability studies, and successfully transition products from pilot-scale development to full production.
• Support and enhance preventive maintenance programs within CMMS to maintain equipment capability and reduce recurring performance losses on critical assets.

Cross-Functional Leadership & Operational Support

• Maintain a strong presence on the production floor, working closely with operators and technicians to provide training, resolve process issues, and reinforce best practices and standardized operating conditions.
• Lead customer complaint investigations, root cause analyses, and corrective and preventive action (CAPA) activities to drive sustainable quality improvements.
• Collaborate with cross-functional leadership to ensure adherence to safety, quality, and regulatory requirements.
• Ensure clear communication across teams by maintaining accurate documentation, action logs, work records, and timely closure of assigned initiatives.
• Audit manufacturing processes to verify compliance with quality standards; develop, maintain, and continuously improve quality systems and procedures while delivering effective training to promote consistent understanding and execution across all functions.

QUALIFICATIONS The requirements listed below are representative of the knowledge, skill, and/or ability required to perform this job successfully. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions.

• Bachelor’s degree in Mechanical, Industrial, Materials, Chemical or a related Engineering discipline.
• 3+ years in manufacturing/process engineering. Experience in plastics film/PVC, ink mixing, web coating and converting preferred.
• Proven ability to develop, implement, and improve process optimization initiatives using standard operating conditions, PFMEA, Control Plans, and change management methodologies.
• Demonstrated CI mindset with the ability to apply Lean/Six Sigma methodologies, root cause analysis, and hands-on troubleshooting to solve problems and drive continuous process improvement.
• Strong ability to manage priorities, solve problems, and drive results.
• Working knowledge of CMMS-driven PM systems and manufacturing equipment reliability practices preferred.
• Skilled in collaborating across teams and influencing outcomes without direct authority.

PHYSICAN DEMANDS & WORKING ENVIRONMENT The physical demands and work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions.

• Onsite role in manufacturing facility with frequent movement between office and production areas. Ability to wear Personal Protective Equipment (PPE) in designated areas.
• Flexibility to adjust work schedule based on operational needs; occasional off-shift support for startups/trials.

ITW is an equal opportunity employer. We value our colleagues’ unique perspectives, experiences and ideas and create workplaces where everyone can develop their careers and perform to their full potential.

As an equal employment opportunity employer, ITW is committed to equal employment opportunity and fair treatment for employees, beginning with the hiring process and continuing through all aspects of the employment relationship.

All qualified applicants will receive consideration for employment without regard to race, color, sex, gender identity, sexual orientation, religion, national origin, age, disability, protected Veteran status or any other characteristic protected by applicable federal, state, or local laws.