Process Engineer

pladis Global•Town of Big Flats, WI

3d•$116,000 - $154,000•Onsite

About The Position

The Process Engineer is a hands-on technical role responsible for developing, scaling, and improving manufacturing processes across R&D and manufacturing. The role leads technical trials, applies scientific and engineering principles to process challenges, and converts data into practical recommendations that improve process capability, product quality, efficiency, capacity, cost, waste, and consistency. Reporting to the R&D Lead, Americas, the role partners with Product Development, Packaging, Engineering, Operations, Quality, Procurement, Supply Chain, Finance, Marketing, suppliers, co-manufacturers, and other external partners. Based on-site in Big Flats, the Process Engineer introduces new products, processes, equipment, and technologies safely and effectively while strengthening process standards and technical capability. The role supports new product development, scale-up, continuous improvement, factory trials, process optimization, equipment selection and commissioning, manufacturing support, quality and compliance, and cross-functional project delivery. It plans and manages trials within approved budgets and site requirements, makes evidence-based recommendations, and shares technical knowledge across teams.

Requirements

Relevant experience in process engineering, process development, technical trials, or process improvement within manufacturing or R&D.
Hands-on knowledge of food or FMCG manufacturing processes and ability to troubleshoot process, equipment, and product interactions.
Experience planning, running, and evaluating factory trials, scale-up, or commercialization activity.
Ability to manage multiple technical priorities and collaborate across functions and manufacturing sites.
Bachelor’s degree in Engineering, Food Science, Manufacturing, or a related technical discipline.
Working knowledge of Lean Six Sigma, SPC, root-cause analysis, process capability, and structured problem solving.
Strong analytical and data-interpretation skills, including the ability to turn evidence into clear recommendations.
Clear written and verbal communication skills, including preparation of technical reports and presentations.
Knowledge of HACCP, GMP, food hygiene, and process-safety requirements.
Technical problem-solving and engineering judgment.
Trial design, scale-up, and commercialization capability.
Process optimization and statistical analysis capability.
Project planning and delivery capability.
Strong stakeholder management, cross-functional collaboration, and influencing skills.
Ability to work in a fast-paced, evolving environment with organization, prioritization, professionalism, and attention to detail.
Results-oriented, hands-on, curious, evidence-led, resilient, adaptable, collaborative, positive, organized, and accountable approach.
Comfort with challenging assumptions and making practical recommendations.
Commitment to technical excellence, safety, quality, and continuous improvement.

Nice To Haves

Lean Six Sigma Green Belt or Black Belt certification.
Experience in bakery, biscuits, snacks, chocolate, or confectionery manufacturing.
Experience designing and running DOE activity to optimize machinery settings or process parameters.
Experience with texture analysis, rheology, or other material-characterization techniques.
Experience supporting equipment selection, capital projects, commissioning, or new technology implementation.
Track record of measurable improvements in efficiency, waste, quality, cost, capacity, or process capability.
Experience working with suppliers, co-manufacturers, or multi-site/global technical teams.

Responsibilities

Translate approved product concepts into robust manufacturing processes from prototype sign-off through factory scale-up and launch.
Plan, coordinate, run, and evaluate factory trials for new products, product changes, procurement initiatives, process changes, machinery, and technology.
Define trial objectives, methods, sampling plans, success criteria, risks, and resources, and communicate conclusions and recommendations.
Develop and maintain process specifications, operating parameters, and manufacturing guidance for new and changed products.
Support product and production transfers between lines, sites, and external manufacturers.
Identify and prioritize opportunities to improve quality, process consistency, efficiency, capacity, cost, and consumer satisfaction.
Apply Lean Six Sigma, SPC, process capability analysis, and structured problem-solving tools to reduce variation and sustain improvements.
Use root-cause methods, including 5 Whys, Fishbone analysis, and evidence-based data review, to address defects, losses, and recurring process issues.
Develop and implement optimization plans and embed improvements in operating procedures, standards, and controls.
Identify and reduce manufacturing waste, including overproduction, waiting, transport, extra processing, inventory, motion, and defects.
Use statistical and analytical techniques to assess process performance and turn trial outcomes into practical recommendations.
Establish and maintain KPIs and SPC measures to monitor capability, confirm benefits, and sustain gains.
Design and execute DOE activity to optimize process parameters, machinery settings, and operating windows.
Apply material and product measurement methods, including texture analysis, rheology, or other appropriate techniques.
Prepare technical reports, presentations, and project updates for stakeholders.
Provide process engineering input into equipment selection, process design, purchase, installation, commissioning, and performance qualification.
Assess manufacturing capability, process risks, operating constraints, and technology requirements before implementation.
Support line trials and start-up for new equipment, ensuring solutions meet productivity, quality, safety, and operational requirements.
Identify potential capital investment opportunities and provide technical evidence, trial data, and recommendations for business cases.
Partner with equipment and ingredient suppliers, co-manufacturers, and subject-matter experts to develop technical solutions.
Provide hands-on technical support for manufacturing challenges and support lines in meeting process, quality, and product standards.
Ensure trials and process changes comply with Health and Safety, chemical-handling, HACCP, GMP, and product-specification requirements.
Provide evidence-based technical input into product disposition decisions arising from trials, within agreed authority.
Build process knowledge and site capability through coaching, standardization, best-practice sharing, and technical documentation.
Build and manage integrated technical plans, dependencies, risks, trial schedules, actions, and decision points.
Deliver initiatives to agreed time, cost, and quality expectations and promptly escalate risks or resource conflicts.
Share learning across sites and teams to harmonize methods, technology, and technical standards.
Provide progress updates and recommendations to the R&D Lead and relevant business forums.
Plan and manage technical trials within approved budgets, governance, and site requirements; recommend trial disposition, process settings, operating windows, corrective actions, and readiness to progress based on evidence.
Prioritize assigned technical activity in alignment with R&D and site leadership and influence stakeholders through data, technical judgment, and practical recommendations.

Benefits

Medical, prescription drug, dental, and vision coverage.
Life and disability insurance.
Voluntary supplemental benefits, including hospital indemnity, accident, and critical illness coverage.
401(k) retirement plan with company match.
Education assistance, including tuition reimbursement and student loan repayment programs.
Paid time off.
Paid parental leave.
Employee Assistance Program (EAP).
Wellness reimbursement program.
Employee product discounts.
Annual incentive opportunity based on individual and company performance.