PRODUCTION ENGINEER

Description

Summary:

The Production Engineer is a hands-on position which provides process technology support to both operating plants and packaging, including reviewing and optimizing systems performances, and writing engineering and validation documents.  The Process Engineer is tasked with providing analysis of processes and leading the improvement projects through feasibility studies, process development testing, implementation, operational start-up, and training. Position oversees environmental compliance, data collection review and deviation/incident analysis.

Essential Responsibilities & Functionsinclude the following, others may be assigned.

Lead the continuous improvement of the processes

• Collect and analyze issues faced by production teams
• Anticipate known development by identifying bottlenecks and high-risks processes, equipment or flows
• Evaluate and propose solutions and their feasibility, eventually with the support of internal and external resources
• Identify and proposes technical or strategic opportunities for improvement
• Maintain and optimize operating guidelines
• Provide processes coaching and trainings to production teams
• Participate in the root cause analysis of technical failures and reliability improvement
• Provide information to R&D and product development teams
• Pilot industrial tests and action plan
• Regularly present to the production teams improvement plans and lead discussions with the involved team members

Analyze the performances of the processes

• Analyze efficiency ratios such as energy, raw materials and material losses, rework and repack, capacity, throughput, Overall Equipment Effectiveness, OEE, and fixed and operating costs
• Create and maintain dashboard and KPIs
• Identify deviations and prioritize action to take according to their impact
• Advise on the best ways to pilot processes based on performances KPI, budget objectives and financial savings
• Can give operational instructions on the way to pilot the process

Prepare study on capital projects and MOC requests

• Participate to the definition of the capital plan and MOC prioritization
• Initiate MOC requests upon manager lead and global capital/MOC plan
• Describe the issue and scope of the project as well as the constraints with the concerned department or supervisor
• Evaluate the risks associated with projects and prioritize accordingly
• Evaluate and justify savings and ROI on projects

Follow up the realization of the capital and MOC projects and coordinate the startup

• Pasrticipate with project leaders and manager macro timeline, critical path
• Provide technical support and process information related with the project development and realization
• Participate in the definition of changes, plans, specifications, process and organizational flows and in the choice of technology, equipment and control design
• Report deviation and identify specific consequences on the improvement plant
• Review and validate PSSR and the action plan completion
• Lead the projects end-user training and relevant procedure revision
• Assess performance and goal achievement

Participate or lead HSQE topics

• Lead risks analysis of project with health and safety, environment, quality and food safety.
• Environment
  • Lead the organization of data collection for environmental control, documentation
  • Perform regular reviews to assess the environmental compliance to permits
  • Identify environmental deviation or opportunity for improvement and propose solutions to department and ESH manager
  • Lead the environmental incident analysis, write and communicate reports appropriately and define corrective and preventive action plan with area supervisor
  • Lead with ESH the environmental audits
  • Lead and follow up the preventive and corrective actions
  • Control the good application of environmental procedures and propose organizational or procedural changes
  • Provide information to ESH department for introducing or renewing environmental permits
• Follow up safety, food safety and quality preventive and corrective actions and integrate them in improvement plan or in the preparation of MOC request
• Quality and food safety
  • Participate in the preparation and follow up of quality, customer and food safety audits,
  • Participate to quasar, claims and CFR analysis
  • Integrate in the scope of projects the related company quality and food safety policies
• Health and safety
  • Participate in the preparation and follow up of health and safety audits
  • Participate in safety incident analysis
  • Integrate in the scope of projects the related company health and safety policies

Must be able to work in excess of eight hours per day or forty hours per week on any shift or travel as needed.  On-call as needed to support 24-hour/7 day per week operational requirements.

Consistently demonstrates prompt, regular and reliable attendance.

Supervisory Responsibilities & Functions

This is a non-supervisory position.

Qualifications

Requirements
Minimum

• Education:       Bachelor’s Degree in Engineering

• Experience:      Three (3) or more years of experience as a Process Engineer in a Chemical manufacturing setting with demonstrated skills in problem-solving/troubleshooting and process improvement.

Preferred

• Education:       Master’s degree in Chemical or Mechanical Engineering

• Experience:      Minimum plus Experience with ASPEN or Data Historian Application

Language Skills
Reading/comprehension, speaking and writing at required education equivalency level.  Ability to read, analyze and interpret general business correspondence, technical/product information, policies/procedures or government regulations.  Ability to complete written forms and write routine to complex procedures, reports and correspondence.  Ability to effectively present information and respond to questions in a group or individual setting.

Mathematical Skills
Requires mathematical skills including proficiency in arithmetic, geometry and algebra, with some requirements for calculus and differential equations. Must be able to analyze data, develop equations and perform mass and energy balance calculations.

Computer Skills
Proficient in Microsoft Office applications, including Word, Excel, and PowerPoint.

Electronic Mail.

SAP or other ERP experience

Aspen or another historian/trend experience (preferred)

Complexity
The work includes varied duties requiring many different and unrelated processes and methods be applied to a broad range of activities and/or substantial depth of analysis within a particular area.  Decisions include areas of uncertainty in approach, methodology, interpretation or evaluation resulting from such elements as continuing changes, technical developments, unknown phenomena or conflicting requirements.  The work requires originating new techniques, establishing criteria, or developing new information.The position requires a working understanding of phosphate manufacturing operations and technical troubleshooting skills including a knowledge of chemistry, mechanical skills, basic electrical and instrumentation skills, distributed and PLC process control systems, material science related to phosphates, PFD and EFD drawings, project management, and unit operations. Project development support function requires knowledge of capital project management process that includes a working knowledge of finance, engineering, and construction.

Physical Demands
The work requires both sedentary and limited physical exertion to include sitting; walking; standing; bending; traversing stairs; carrying of light items such as papers, books or small parts; driving an automobile, forklift, etc. Work routinely requires speaking and hearing (expression or exchanging ideas by means of spoken words and perceiving sounds by ear).

Must be able to work long hours in a manufacturing environment that includes high heat and humidity. Must be able to work “hands on” in troubleshooting process and equipment problems. Must be able to climb stairs.

Work Environment
The work environment requires normal safety precautions typical of such places as offices, meeting and training rooms, personal or commercial transportation methods.  Requires use of safe work practices with office equipment, avoidance of trips and falls, observance of fire regulations and traffic signals, etc.  Generally, the work area is well lighted, heated and ventilated.  Also includes work that requires special safety precautions such as working around moving parts, carts or machines or with irritant chemicals.  Employee may be required to use protective clothing or gear such as masks, gowns, coats, safety shoes, boots, goggles, gloves, safety glasses or shields.