Sr. Process Engineer

Job Locations US-VA-Winchester
Job ID
Regular Full-Time


Kingspan Insulation is looking for a Senior Process Engineer.   This key role will be responsible for developing and managing continuous production processes in a high-output XPS manufacturing operation in Winchester, VA.  You will be instrumental in the optimization of output, quality and cost goals of the organization through data collection and analysis, and then making recommendations for improvements.  You will be a vital participant on projects critical to innovation, development and business growth.

With its US headquarters in Atlanta, GA, Kingspan Insulation, is a leading manufacturer in energy efficiency and moisture management products, offering high performance insulation, building wraps and pre–insulated HVAC ductwork. The vast product range includes optimum, premium and high performance rigid insulation products which have many advantages over traditional insulation materials. Its products are among the most thermally efficient and technically advanced insulation materials available.


Kingspan manufactures extruded polystyrene (XPS) insulation board in the USA, through its primary site in Winchester, Virginia under the GreenGuard® brand name. The company has invested significantly in state of the art manufacturing facilities to expand its overall XPS manufacturing capacity in the USA and in Europe to complement other products manufactured by the Kingspan Group.

You will have the ability to develop opportunities to reduce manufacturing costs; improve product quality and technical performance; improve process optimization and reliability, and develop new products.

You will enjoy the financial stability and security of a global company, but with the environment and administration of a smaller business. With a friendly culture, advancement and growth opportunities, and above average benefits, you’ll want to stay for the long term at Kingspan Insulation.


As a member of the team, you can expect: 

  • Competitive base salary + bonus
  • Outstanding benefits – Including Paid Time Off (PTO), medical, HSA, FSA, dental, vision, supplemental insurances, short term disability, long term disability, life insurance, identity theft protection, 401k with 100% matching up to 6% of annual wages, plus an additional 2% annually.
  • Smaller company feel – Although this is a global company, the US is responsible for running its own division. This means less red tape and bureaucracy, making your work life easier. 
  • Relocation assistance to the Winchester, VA area available.

Key Duties Include

  1. Responsible for developing and improving manufacturing foam extrusion processes, maximizing production yields and quality while minimizing waste and cost.
  2. Recommends changes or upgrades to equipment, work methods, or other aspects of the process to improve efficiency and utilization of resources including labor, energy and raw materials.
  3. Identifies process bottlenecks and devises solutions to resolve.
  4. Provides engineering support to maintain, evaluate and improve processes in a continuous and complex manufacturing environment. Ensures Production Manager and Supervisors receive the support they need from the engineering group in order to accomplish production goals.
  5. Communicates and coordinates with supervisors, managers, technicians and operators to continually improve manufacturing processes by minimizing material usage, while still maintaining quality.
  6. Acts as a knowledge resource and guide for less experienced engineers, as well as technicians and operators.
  7. Creates and maintains accurate engineering/process documentation of product specifications, Process Flow diagrams, Process Failure Modes and Root Cause Analysis.
  8. Works on development of critical business opportunities, both locally and divisionally. Leads and supports pilot line trials that lead to development of new and/or improved products for the Insulation Division in the US and Europe.
  9. Oversees quality control processes for the organization. Creates, reviews and monitors adherence to manufacturing and quality standards while optimizing productivity and exceeding customer expectations.
  10. Establishes and maintains SOPs for maintaining high standards of productivity, quality, reliability and safety in manufacturing, product designs and/or existing engineering applications.
  11. Assists in the completion of environmental forms and other environmental responsibilities.
  12. Communicates with line supervisors and operators in order to develop training modules on procedures and process corrective actions.
  13. Member of, and actively participates in, the organization’s Innovation Development System and stage-gate process.
  14. Coordinates and/or provides training for the engineering, maintenance or production group.
  15. Supervises Process Technicians and Quality Technicians.
  16. Completes special projects.

Supervisory Duties: Carries out supervisory responsibilities in accordance with the Company's policies and applicable laws.


Skills, Knowledge & Abilities


Education and/or Experience: BS in engineering, preferred 7-10 years of experience in a manufacturing environment. Prefer someone with at least five (5) years of experience in plastics and/or foam extrusion or chemical experience. Experience in Lean manufacturing with a history of leading problem solving activities preferred. SAP or similar software experience preferred.

Must have:

  • Experience with business computer applications (Microsoft Office).
  • Thorough knowledge of production process to include forming/extrusion.
  • Strong leadership skills and problem solving ability. Strong communication skills, effective interpersonal and conflict resolution skills.
  • Working knowledge of production environments and safety procedures.
  • Positive pro-active attitude that is both collaborative and team-oriented with a strong work ethic.

Must be able to:

  • Demonstrate troubleshooting and problem solving ability.
  • Must be able to effectively operate building product equipment with complete understanding of all involved processes.
  • Work in a team based environment.
  • Be flexible with hours worked, working "on call as needed" including evenings, early mornings, and weekends.
  • Set and manage multiple priorities.
  • Follow directions and get along well with others.



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