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Process Engineer
The Process Engineer III will implement World Class Manufacturing (WCM) projects, production and processing methods and controls to meet customer based quality standards in a manner consistent with Gypsum Vision, Mission, Values and Objectives (VMVO). Utilizing WCM principles, this position will focus on product formulation, process development and optimization, equipment design and optimization, general project engineering, and trial planning and execution.
The Process Engineer III will also support the plant and company strategic initiatives including capital projects that involve process improvements, sustainability and new product development. Through the application of process engineering fundamentals and advances process control tools, this position will ensure that processes are centered, capable and in control; reduce process variations; and resolve special causes variation.
ESSENTIAL DUTIES
- Reports directly to the Process Control Manager
- Analyzes process variations; develops solutions and implements corrective actions by using advanced statistical tools in identifying and resolving the root causes of the variations in the process, and participates in resolving critical process and product problems with customers and vendors.
- Responsibilities include the designing / developing new process systems, revising existing processes, and developing and coordinating the implementation of projects, which contribute substantially to plant profitability.
- As primary project leader, provides technical direction to designers, contractors and employees of associated projects.
- Interacts with Team for operational trouble-shooting, process improvement projects, production materials requirement, raw material availability and Quality Step Zero requirements.
- Compiles technical data and other background information to determine equipment performance specifications and established baselines. Interprets and extrapolates accumulated data to prepare diagrams and flow charts for the efficient operation of the equipment.
- Lead the WCM Pillar for Early Equipment Management (EEM) and be a senior advisor for Focused Improvement and Professional Maintenance teams.
- Assists with preparing programs for computer control systems.
- Interacts with consultants and suppliers to determine compatibility of other systems and products as they may apply to process improvement.
- Implements recommended process efficiency improvement projects.
- Ensure Gypsum’s standards of safety, quality and reliability are built into process and equipment solutions utilizing WCM principles.
- Develop best practices, routines, standards and innovative solutions to improve production rates and quality of output.
- Write /Analyze capital expenditures and project designs to help find ways to cut costs and improve process/quality.
- Works with project teams during delivery phase and commissioning of equipment.
- Develops and encourage innovative processes and equipment concepts along with follow through to Return on Investments (ROI) patents and / or proprietary intellectual property.
- Identifies safety, cost and quality opportunities and develops solutions for corrective actions.
- Analyzes operating problems, develops solutions, and leads the implementation of corrective actions.
- Organizes and initiates run trials to evaluate equipment, process and raw material opportunities.
FISCAL RESPONSIBILITY
- Responsible for capital project budget from planning to execution.
- Prepares capital expenditures and provides technical and budgetary input for the purpose of planning and scheduling projects.
WORKING CONDITIONS
Works in a manufacturing plant environment with limited HVAC, concrete floors, and exposure to industrial noise, dust, chemicals and temperature changes. Normal plant operation is 24 hours, 7 days a week and work hours may vary depending on business needs. May require long hours, and weekend and holiday work. May require travel by air and rental cars.
PHYSICAL DEMANDS
Must be able to spend a significant amount of time on plant floor. Job includes tasks that require walking, bending, twisting, gripping, stair and ladder climbing, entering confined spaces, navigating rough terrain and occasional lifting of up to 50 lbs. Job may require long periods of sitting, walking, standing, working on a computer or engaging in telephone conversation. Must be capable of wearing personal protective equipment necessary to comply with government and company safety standards whenever engineered methods of reducing hazards or physical requirements cannot be reasonably accommodated.
MINIMUM KNOWLEDGE AND SKILLS REQUIRED
- Bachelor’s Degree in chemical engineering, chemistry or similar discipline; or five (5) years of equivalent training and experience to have comprehensive knowledge of the practices, procedures and regulations associated with process control technology may be substituted for a degree.
- Five to ten (5-10) years of applied professional process experience in a manufacturing environment.
- PEng designation is mandatory
- Statistical Analysis skills including use statistical analysis tools such as Minitab.
- Two to three (2-3) years of experience in project management and project engineering fundamentals.
- Previous experience with product formulation, water and foam chemistries, mass & energy balance, flow diagrams, Process & Instrumentation Diagrams (P&ID), fluid properties and thermodynamics.
- Working knowledge of advanced statistical tools used to reduce variations.
- Flexible, open-minded team player with excellent written and verbal communication skills.
- Excellent interpersonal and problem solving capabilities to work effectively in corporate, manufacturing and team environments.
- Ability to provide leadership and innovation at all levels of the organization.
- Proficient in Advanced Microsoft Office Suite. Previous AutoCAD experience.
- Experience in gypsum chemistry and manufacturing process.
- Experience leading focused improvement (FI) or Kaizen projects
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