Job purpose
The Senior Process Engineer will design, develop, and implement new or revised processes to support new or legacy product innovation and drive continuous improvement initiatives including safety, product quality, consistency, cost reduction, higher efficiency, and greater machine utilization performance. The position is for a Senior professional who applies advanced knowledge of a job area typically obtained through continued education and work experience. Problems faced are difficult and complex requiring advanced problem-solving skills. The position could support multiple sites and travel is required as necessary.
Duties and responsibilities
- Transition new products through development of effective manufacturing processes and equipment operation working collaboratively with a multi-functional team to achieve success.
- Perform trials, studies and capability analyses as needed to effectively understand and improve process capabilities. Demonstrate use of statistical methodologies to understand, analyze and drive reduction in process variation in facilities.
- Lead in the Commissioning, Qualification & Validation (CQV) to ensure effective transition of new or modified products into manufacturing. Ensure proper documentation through the Holcim 3M or RADAR processes when appropriate.
- Analyze production performance results and implement improvements. Lead KAIZEN events.
- Investigate critical quality issues and customer complaints as requested. Interface frequently with the Quality Department on corrective actions.
- Support development and implement action plans for continuous improvements and cost savings. Optimize production line processes by driving safety, quality & efficiency.
- Perform risk assessments as needed with EHS. Support documentation for Management of Change (MOC). Perform HAZOPs, PHAs or Design Safety Reviews as needed to support new or modified equipment.
- Maintain & control plant recipes/formulations in plant operating systems (i.e. Ignition, Shopfloor, etc.). Update as necessary and ensure accuracy.
- Ensure technical accuracy for PFMEAs and Process Control Plans (PCPs) for assigned sites. Update and maintain process documentation.
- Train operators and supervision on the proper operation of equipment and processes.
- Execute other duties as assigned.
Qualifications
- Bachelor's degree in Engineering or a related technical field, preferred degree in Chemistry, Chemical, Electrical, Mechanical or Industrial Engineering
- Five or more years of engineering or plant manufacturing experience in related manufacturing industries
- Excellent verbal and written communication skills
- Strong analytical, troubleshooting, and problem-solving skills
- Experience in Statistic Process Control, DOE, TPM, PFMEA and Lean/Six-Sigma manufacturing methodologies. Six-Sigma certification is a plus
- Experience with Management of Change (MOC), PHAs and HAZOPs
- Strong office tool skills, including MS Office suite and statistical analysis tools like Minitab
- Travel as needed to support multiple locations
Working conditions
The working conditions include manufacturing office as well as dusty, non-airconditioned industrial manufacturing and warehouse areas. Working temperature can vary with seasons and be especially hot in areas of the plant. Occasional work is required in outdoor activities in hot or adverse weather.
Travel Requirements: Up to 50% if multi-site responsible
Physical requirements
Must be able to lift 50 pounds. Must be able to climb ladders, railcar platforms, lift and carry hoses, kneel, bend reach and stoop. Periodic periods of prolonged sitting and data analysis work.
