Process Engineer

About the position

Provide technical expertise and day-to-day engineering support to the manufacturing facility. This will include interaction with the operations and maintenance employees to design and modify existing and new facilities for the purpose of plant continuous improvement. This individual must play an active leadership role in the site’s Manufacturing Excellence Program with accurate measurement and tracking of key performance metrics such as yield, cost, quality, and efficiency (OEE) and to strengthen the mindsets and behaviors at the site to sustain the improvements.

Responsibilities

• Change Agent for the site; help lead Manufacturing Excellence initiatives to improve the site performance and culture
• Analyzes quality for multiple product lines utilizing statistical control charts. Works toward establishing ‘in-control’ processes. Identifies areas of variation (raw materials, process, or quality analysis), implements measures to reduce variation, and tracks effectiveness of reduction measures.
• Analyzes process data and quality critical parameters for control of manufacturing processes. Troubleshoots problem areas and identifies measures for improvement.
• Investigates off-grade or abnormal batches. Identifies root cause, reports findings, and implements corrective actions.
• Use heat and material balances, fluid flow/hydraulic principles to troubleshoot process problems and design new equipment.
• Analyzes batch cycle times. Identifies and implements process optimization improvements to establish consistent cycle times and reduce overall cycle times to lead to improved capacity at the site.
• Reports cycle time, Overall Equipment Effectiveness (OEE) and other key metrics for key equipment and key product lines.
• Utilize management of change for applicable situations.
• Evaluate raw material changes for impact on quality. Develop studies/protocol for evaluation prior to introduction.
• Trains production operators and laboratory technicians on unit operations, chemistries, and batch recipe or DCS changes/enhancements in regards to product line.
• Responsible for day to day troubleshooting and ‘firefighting’ associated with product line.
• Support / adhere to all quality system requirements, including ISO 9001, European Federation for Cosmetic Ingredients (EFfCI), Good Manufacturing Practices and Roundtable for Sustainable Palm Oil (RSPO), consistent with Manufacturing Excellence and HSSE Management Systems as it relates to this position.
• Performs feasibility studies for technology transfers and new product introduction. Includes assessment of current equipment capabilities, HSE issues, capital requirements, and quality assurance capabilities.
• Provide process engineering support for capital and automation projects.
• Provides process engineering assistance to help the plant define and solve problems and capitalize on their opportunities within a leadership role as part of the site’s Manufacturing Excellence Program.
• Provide leadership in a process improvement team setting.
• Influence people’s opinions, attitudes, and judgments and demonstrate the ability to compromise opinion to develop the best solution for the issue.
• Processes run within defined control limits
• Production rates and cycle times are optimized
• Site complies with Corporate safety programs and passes internal and regulatory audits
• Provide all required management and technical documentation as needed for the site and regulatory compliance.
• Be a liaison between the plant (client) and the site technical team.
• Systemic problem areas (particularly safety) are identified and corrected in a timely fashion.
• Individually, as well as in a team, provide cost effective process designs and troubleshooting for numerous projects.
• Provide timely and accurate scope definition and project description to develop a RACE (Capital authorization request).
• Have a working knowledge of process piping, pumps, electrical and instrumentation/control systems.
• Able to perform a variety of duties, often changing from one task to another of a different nature without loss of efficiency of composure.

Requirements

• Minimum 3 years of engineering experience in Process and/or Production Engineering areas
• Minimum of BS ChE preferred, other engineering disciplines considered
• Excellent written and oral communication skills
• Chemical industry background, surfactants & Batch Processes preferred
• Familiarity with engineering and safety standards – i.e. OSHA PSM & EPA RMP
• Must be able to analyze, troubleshoot and solve problems with innovative approaches to problem solving.
• Must be proficient in the use of engineering spreadsheets/calculations
• Individual must be organized, systematic, independent, and self-motivated.
• Be able to manage and lead process improvement teams in the plant
• Process design experience to help with Capital Project Scoping. (Equipment sizing, heat loads etc.)
• Professional Engineer Stamp a plus but not required

Benefits

• Competitive and comprehensive health, dental and vision benefits through Cigna.
• Generous matching 401k plan
• Flexible Spending Account (FSA)
• Health Savings Account with employer contribution and yearly roll over (cannot be combined with FSA)
• Health advocacy and services
• Company paid life insurance
• Company paid short term disability insurance
• Paid Vacation and Holidays
• Employee Assistance Program
• Company discount programs available including discounts on gym membership and equipment, hotels, rental cars, etc.