Sr Process Improve Engineer
About The Position
The Senior Process Improve Engineer identifies, evaluates, and implements process, technology, reliability, and continuous-improvement opportunities at the Gastonia site. The role provides day-to-day process engineering support, leads data-driven gap closure, supports product and process scale-up, and represents Manufacturing technically throughout project definition, design, commissioning, and start-up. It works closely with Operations, Maintenance and Reliability, HSES, Quality, R&D, Product Safety, project engineering, and technology experts to support safe, robust, standardized, and capable manufacturing processes. The position reports directly to the Process Improve Manager. The engineer monitors process performance and production losses, troubleshoots manufacturing issues, and recommends changes to procedures, equipment, controls, or recipes. The role leads continuous-improvement and technology activities, supports capital projects and technical integrity, and partners with R&D and cross-functional teams on product development, trials, scale-up, and commercialization. It also champions process safety and supports applicable management systems, documentation, change control, and audits.
Requirements
- Bachelor's degree in an engineering discipline.
- At least 4 years of process, manufacturing, technology, or improvement engineering experience in a chemical or process-manufacturing environment.
- Experience working with cross-functional teams in process improvement, new-product development, technology transfer, scale-up, capital projects, and plant operations.
- Working knowledge of statistical process control, process capability, root-cause analysis, experiment design, and data-based problem solving.
Nice To Haves
- Chemical Engineering degree is strongly preferred.
- Familiarity with OSHA Process Safety Management.
- Experience with ISO 9001 and RC14001.
- Experience with DeltaV, SAP S/4HANA, and regulated or certified manufacturing systems.
Responsibilities
- Monitor process capability, product performance, batch history, production losses, cost variances, and recurring failures to identify and prioritize improvement opportunities.
- Provide process troubleshooting and technical direction to Operations, including support outside normal business hours when required.
- Recommend and implement procedural changes, equipment modifications, process-control improvements, or recipe adjustments to reduce variability and improve Safety, Environmental, Quality, Delivery, and Cost performance.
- Maintain and standardize manufacturing, operating, and cleaning instructions; train and coach process operators on technical and process changes.
- Partner with Maintenance and Reliability to improve equipment performance, operability, and reliability.
- Lead continuous-improvement activities, opportunity evaluation, gap closure, internal benchmarking, and project scope definition.
- Analyze plant and business data to maintain a prioritized improvement opportunity list aligned with site and business objectives.
- Identify and apply Most Effective Technology and relevant internal or external practices that create measurable value.
- Support development and execution of multi-year process and technology plans for the assigned plant, unit, or technology area.
- Use statistical process control, designed experiments, and other analytical methods to improve process capability and sustain results.
- Serve as the manufacturing technical representative through Front-End Loading, design, commissioning, start-up, and post-start-up stabilization as assigned.
- Develop project scopes and gap-closure plans with Operations, HSES, Quality, technology experts, and Maintenance and Reliability.
- Integrate operability, process safety, reliability, and technology requirements into project definition and design.
- Provide technical justification and start-up support for capital projects and coordinate between project teams and plant Operations.
- Maintain accountability for the technical integrity and operability of supported processes and units.
- Serve as the liaison between Manufacturing and R&D for new products, raw materials, process changes, and technology transfer.
- Plan and support laboratory, pilot-plant, toll-manufacturing, and commercial-scale trials; analyze data and communicate conclusions and recommendations.
- Lead or coordinate new product trials, process scale-up, product realization, and process-capability improvement activities.
- Collaborate with scientists, engineers, account managers, product management, Quality, and Operations to achieve safe and successful commercialization.
- Champion process safety in process changes and project design and partner with Operations to maintain robust, safe manufacturing processes.
- Support and maintain applicable systems and requirements including PSM, MOC, PHA, PSSR, JSA, RCA, incident reporting, ISO 9001, RC14001, and cGMP.
- Update and standardize process instructions and ensure technical changes follow site change-control, risk-assessment, and documentation requirements.
- Serve as a technical representative for customer, certification, and management-system audits as required.
Benefits
- Competitive salary with performance-based bonus plans.
- 401(k) match and age-weighted defined contribution.
- Comprehensive medical, dental, and vision coverage.
- Health Savings Account (HSA).
- Paid holidays, vacation, and parental leave.
- Flexible work environment.
- Learning and development opportunities.
- Career and professional growth.
- Inclusive culture and community engagement.
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What This Job Offers
Job Type
Full-time
Career Level
Mid Level
