Process Engineer

What are we looking for?

The Process Engineer will collaborate with the Operations Team to improve efficiency of the Roebuck manufacturing process through cost reduction, value creation, improved process capability, and process equipment reliability. This role includes elements of process improvement, process and equipment troubleshooting, project management, and site support of process control systems and process equipment. Additional expectations include optimization of mechanical systems and safety related initiatives.

What you’ll own in this role:

This is a broad role with responsibilities in several traditional engineering roles:

Process Improvement – 75%

• Support manufacturing in trouble-shooting and response to process upsets
• Liaison with R&D to scale up new technologies and processes
• Identify and execute/lead projects such as:
• Improve cycle time
• Reduce process downtime and cleaning time
• Reduce energy usage
• Improve process capability
• Reduce reactor fouling, yield loss, filtration time/materials

New Product Introductions – 15%

• Work with Synthomer R&D employees to translate lab-scale processes to the commercial scale reactors
• Write new batch recipes, edit and improve existing batch recipes
• Communicate closely with Ops Team to mistake-proof batch recipes
• Document new product introductions and lead scale-up reviews with R&D Team

Process Control Support – 5%

• Support DCS system routine maintenance, updating, and documentation needs
• Manage lifecycle of control systems, including forecast of capital needs.
• Provide programming support to supplement site capital projects.
• Maintain and improve site OSI PI deployment.

Safety / Health / Environmental Improvement – 5%

• Lead or actively participate in Process Safety Initiatives and other site safety initiatives
• Provide engineering support for safety and environmental improvement projects

Expected Results

Set annual goals (with your manager) and review progress routinely to adjust to business and site needs. Annual goals may include:

• Implement identified site improvement initiative (such as improving compliance to regulation or using new procedures, equipment, or methods)
• Identify, sell, and champion new improvement ideas
• Support specific equipment and maintenance functions, such as instrumentation, controls, pressure vessels, environmental controls, or electrical systems
• Participate in or lead initiatives to improve site safety culture and performance

A process engineer at the Roebuck site may be assigned specific responsibilities for which he/she will be primarily responsible, including process improvement, or control system management. Although this responsibility will be the primary focus, it is expected that all Roebuck site engineers engage in some level of all key plant operations functions, including safety process improvement, process optimization, maintenance troubleshooting, and quality customer fulfillment.

This role is a feeder to positions of higher responsibility. In addition to specific annual goals, the process engineer will identify core and functional competencies to be improved annually.

What you’ll need to be successful:

• Minimum BS Chemical Engineering or related technical degree.
• Understanding and support of the site safety culture and improvement efforts.
• More than 3 years of hands-on chemical manufacturing experience preferred. Experience in batch emulsion polymer production preferred. Delta V Control System experience preferred.
• Customer focus. Ability to adjust efforts to meet the needs of internal and external customers.
• Ability to employ analytical/statistical tools (eg. DOE, Six Sigma) in problem resolution and process optimization.
• Skilled and experienced in addressing multiple priorities/projects with minimum direction while prioritizing and maintaining focus.
• Energetic; demonstrated initiative and drive; results oriented.
• Team-oriented collaboration and interaction across functional roles to accomplish common goals or to advance site initiatives. Must have communication and leadership skills to lead small work teams
• Willing to work outside of normal hours and on weekends for project management or start-up.
• Occasional travel may be required.

Other Essential Criteria:

Must be able to support and be aligned with business goals by contributing to the Company’s quality objectives. Must be able to lead and participate in a team environment. Ability to wear safety equipment as required. Ability to respond to calls and solve problems during off-shift hours. Must be able to satisfy the Core Competencies for the role

Physical Demands:

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

Employee must be able to wear required safety equipment including but not limited to steel toed shoes, hard hat, safety glasses, goggles, hearing protection, and fall protection.

While performing the duties of this job, the employee is frequently required to use hands to finger, handle, or feel; reach with hands and arms; and talk or hear. The employee is occasionally required to stand; walk; climb stairs; sit; and stoop, kneel, or crouch. The employee is rarely required to climb ladders. The employee must occasionally lift and/or move up to 20 pounds, and rarely lift and/or move up to 55 pounds. Specific vision abilities required by this job include close vision, distance vision, color vision, peripheral vision, depth perception, and ability to adjust focus.

Work Environment:

The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.

While performing the duties of this job, the employee is occasionally exposed to wet and/or humid conditions, moving mechanical parts, and toxic or caustic chemicals. The noise level in the work environment is moderately quiet.