We are seeking an experienced Process Improvement Engineer with a strong background in carded needle-punch nonwoven manufacturing and fiber processing. This role will focus on improving the performance, consistency, efficiency, and quality of carded needle-punch nonwoven manufacturing processes. The successful candidate should understand how fiber characteristics and processing conditions affect carding, needle-punching and final nonwoven product properties. This is a hands-on manufacturing position requiring significant interaction with production equipment, operators, technicians, and engineering teams. Key Responsibilities • Lead process improvement initiatives for carded needle-punch nonwoven manufacturing processes. • Optimize processes from fiber preparation and blending through carding, web formation, crosslapping, needle punching, and finishing. • Troubleshoot issues related to fiber opening, blending, fiber distribution, web uniformity, basis weight, thickness, density, and product consistency. • Optimize carding and web-forming conditions to achieve consistent fiber distribution, orientation, web weight, and uniformity. • Optimize needle-punch parameters including needle density, penetration depth, punch frequency, stroke, and line speed. • Evaluate the impact of fiber type, fiber length, denier, crimp, finish, blend ratios, and recycled content on manufacturing performance. • Conduct plant trials and process experiments involving new fibers, fiber blends, equipment settings, and process conditions. • Identify and eliminate root causes of scrap, defects, downtime, rework, and process variation. • Analyze manufacturing data to identify opportunities to improve throughput, yield, quality, and material utilization. • Establish and maintain appropriate process windows, operating standards, and process controls. • Use structured problem-solving methodologies including Root Cause Analysis, 5-Why, Fishbone, SPC, DOE, Lean, and Six Sigma tools. • Work with Maintenance and Engineering on equipment modifications and improvements. • Support new product development and commercialization by establishing repeatable manufacturing processes. • Develop and maintain SOPs, work instructions, process specifications, and control plans. • Train and support production personnel on optimized process conditions and standard operating procedures. • Track and quantify process improvement results, including cost savings, scrap reduction, productivity, yield, and capacity improvements. Requirements • Bachelor's degree in Textile Engineering, Chemical Engineering, Mechanical Engineering, Materials Science, Manufacturing Engineering, or a related technical field. • 5+ years of experience in process improvement, process engineering, or manufacturing engineering. • Strong hands-on experience in nonwoven manufacturing and fiber processing. • Direct experience with carded needle-punch nonwoven processes. • Strong understanding of fiber processing, carding and needle punching. • Experience working with synthetic fibers and fiber blends, such as polyester/PET, polypropylene, or recycled fibers. • Experience troubleshooting manufacturing problems directly on the production floor. • Demonstrated experience improving manufacturing throughput, yield, quality, process capability, and material utilization. • Strong analytical and problem-solving skills with the ability to use manufacturing data to identify root causes and implement solutions. • Experience with Lean Manufacturing, Six Sigma, SPC, DOE, and root-cause analysis. • Strong communication and collaboration skills. Ability to work effectively with Production, Operations, Maintenance, Quality, R&D, and Engineering teams.