Process Safety Engineer

Dsj Global - Gurnee, IL

Full-time

Gurnee, IL

Administrative and Support Services

About the position

The Process Safety Engineer role is crucial for leading and supporting the site's Process Safety Management (PSM) strategies. This position focuses on establishing a robust PSM program aimed at enhancing safety, environmental performance, and operational efficiencies. The engineer will work collaboratively with various teams to implement best practices, ensure compliance with regulations, and drive continuous improvement in process safety.

Responsibilities

• Devise and implement PSM standards, incorporating best practices from other sites.
• Support compliance with OSHA, PSM, and RMP regulations.
• Compile and manage process safety information (PSI) to support process safety, management of change, training, risk assessments, and emergency response activities.
• Ensure process safety documentation for all identified hazards is developed and maintained, including reviewing and organizing P&IDs and PFDs.
• Lead the site's Process Hazard Analysis (PHA) program to identify, evaluate, and control potential process hazards.
• Ensure an annual program of PHAs is compiled and adhered to, including closing out actions related to PSM and completing annual site internal audits.
• Facilitate or participate in PHAs, safety integrity level (SIL) studies, introduction of new raw materials, MOCs, and PSSRs as required.
• Review MOCs for PSM-related items and ensure PSSR (Pre-Startup Safety Review) completion for all MOCs.
• Provide engineering technical input into process design and hazard studies.
• Act as the site point of contact for all process safety-related matters, providing day-to-day advice and guidance.
• Participate in and/or lead incident investigations related to PSM/RMP-covered processes, ensuring root causes are identified and addressed.
• Participate in PSM/RMP compliance audits, oversee post-audit corrective/preventive actions, and track them to completion.
• Track site KPIs to drive continual improvement of process safety and risk mitigation.
• Identify process safety training needs and provide training through in-house resources or external consultancy.
• Provide technical support to ensure PSM equipment is designed, maintained, modified, operated, and decommissioned in compliance with industry standards.
• Work closely with all disciplines to identify improvement opportunities and ensure plant processes are optimized.
• Ensure safe processes, work conditions, and behaviors through active leadership in Safety, Health, and Environment (SHE).
• Provide process engineering support to all aspects of operations, guiding new equipment design and commissioning, introducing new products, and solving process issues.
• Work with project engineers and external contractors to introduce new equipment and develop and commission new processes.
• Apply LEAN, Six Sigma, and other Continuous Improvement tools and techniques as required.
• Provide guidance to production supervisors and engineers, offering training and coaching as needed.

Requirements

• Bachelor's degree in Chemical Engineering.
• Minimum of five years of experience in the chemical industry, with emphasis on participating in and/or managing a PSM program.
• Experienced PHA and LOPA facilitator.
• Experience with Six Sigma, Lean Enterprise, and Continuous Improvement projects is desired.
• Six Sigma certification is preferred but not essential.
• Exposure to ISO, cGMP, and Food Safety quality systems is preferred.
• Excellent organizational and leadership skills.
• Strong analytical, critical thinking, and problem-solving skills.
• Ability to identify root causes and implement corrective actions.
• Strong time management, record-keeping, project leadership, and organizational skills.
• High level of emotional intelligence to influence and work in cross-functional teams.
• Excellent communication skills (oral and written).
• Proficient in MS Office Suite applications (Excel, Word, PowerPoint, and Outlook).

Nice-to-haves

• Six Sigma certification is preferred but not essential.
• Exposure to ISO, cGMP, and Food Safety quality systems is preferred.