# Senior Process Improvement Engineer - 1481

> SP Associates · Dalton, United States · — · Posted 2026-10-06

**Workplace:** on_site

## Description

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.

## Apply

[Apply at SP Associates](https://apply.workable.com/sp-associates/j/B193852D48/apply)

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