Process Improvement Engineer

$72,500 - $121,300/Yr

PepsiCo - Aiea, HI

Full-time - Mid Level

Aiea, HI

Beverage and Tobacco Product Manufacturing

About the position

The Process Improvement Engineer (PIE) plays a crucial role in enhancing the reliability and efficiency of manufacturing operations, particularly in the packaging of PET bottles. This position requires a strong foundation in mechanical and process engineering, along with a solid understanding of control logic and operational principles. The PIE is tasked with maintaining and improving manufacturing reliability, True Efficiency (TE), Running Efficiency (RE), and overall production system capabilities. The role demands a proactive approach to identifying and implementing improvements that lead to measurable enhancements in safety, quality, cost, and productivity. In this role, the PIE collaborates closely with Operations, Engineering, and Maintenance teams to deliver improved results. They are responsible for developing a deep understanding of the assigned processes, leveraging this knowledge to enhance TE, quality, yield, and throughput. This includes analyzing the physics and chemistry of production systems, understanding their limitations, and assessing the impact of variations on throughput, reliability, yield, and quality. The PIE is expected to utilize various methodologies and tools to analyze data related to downtime, rate, yield, and quality loss, and to develop and execute improvement plans accordingly. Specific responsibilities include providing detailed reliability and variability downtime analysis, managing Line Performance Boards, and developing TE/RE improvement processes. The PIE will also be involved in rapid changeover activities, analytical troubleshooting, and process capability studies. The position requires a commitment to continuous improvement and the ability to lead initiatives that drive operational excellence in manufacturing processes.

Responsibilities

• Work closely with Operations, Engineering & Maintenance to deliver improved results.
• Deliver measurable improvements in Safety, People, Quality, Cost, and Productivity.
• Develop mastery and understanding of assigned processes to improve TE, quality, yield, and throughput.
• Analyze planned and unplanned downtime, rate, yield, and quality loss data.
• Lead loss analysis and TE improvement plan development and execution.
• Manage the Centerline System, including its development and change management.
• Implement quality improvement processes and validate quality measures.
• Lead rapid changeover activities to reduce changeover time.
• Conduct analytical troubleshooting and problem-solving activities.
• Perform process definition and capability studies.

Requirements

• BS Degree in Engineering or related discipline required.
• 5+ years of manufacturing experience in a consumer products manufacturing operation.
• Ability to conduct assessments, audits, and evaluations to measure progress.
• Solid problem-solving and action planning skills.
• Effective oral and written communication skills.
• Solid understanding of variable and period costs.
• Self-motivated, results, and action-oriented.
• Ability to make independent and sound decisions.
• Solid interpersonal skills.
• Experience with Systems Controls maintenance, troubleshooting, and modification, including Allen Bradley and Siemens systems.

Nice-to-haves

• Familiarity with TPM pillars such as FI, AM, PM.
• Experience with product development testing and early equipment management tools.
• Knowledge of package material evaluation and qualification processes.
• Understanding of the CQV process (Commissioning, Qualification, Verification).
• Familiarity with OSHA, MSDS, and GMP requirements.

Benefits

• Medical, Dental, Vision insurance coverage.
• Disability insurance.
• Health and Dependent Care Reimbursement Accounts.
• Employee Assistance Program (EAP).
• Insurance options including Accident, Group Legal, and Life insurance.
• Defined Contribution Retirement Plan.
• Paid time off including parental leave, vacation, sick leave, and bereavement leave.