Process Engineer

2 months ago

Conway, United States Westrock Coffee Company Full time

Position Summary

This position is intended to work with Process of Continuous Flow Manufacturing such as convert a formulation or recipe of ingredients using processes such as a chemical or biochemical reaction, heat, cold, mixing, fluidization, crushing, pulverization, screening, sieving, centrifugation, fermentation, distillation, separation, crystallization, evaporation, gas absorption, filtration, diafiltration, polymerization, isomerization, homogenization, pasteurization etc continuously or in a batch to make a final product which is usually a liquid, powder or solid.

Principal Job Functions:

  • Maintains Safety as the number one priority in conducting daily responsibilities, responding to production crew needs, and developing and implementing process improvements for quality, waste and productivity improvement.
  • Supports the World Class Operations Management implementation as an active participant on teams and/or pillars.
  • Investigates causes of ongoing process, quality, production efficiency and high waste problems. Then develops solutions using problem solving techniques.
  • Design and development of a continuous manufacturing process along with the layout and equipment for a new or current factory designs. This includes creating and setting specifications, developing, implementing and monitoring this equipment as part of the manufacturing system.
  • Commissioning and qualification of that new or modified factory
  • Modify and optimize equipment and processes that are already in place
  • Use of simulation software in the development of new processes
  • Completion of documentation to show and ensure compliance with both internal and external regulations and protocols
  • Oversight of processes and working to maintain optimization of the continuous manufacturing process
  • Monitoring of equipment – including regular testing and ensuring maintenance tasks are carried out
  • Assisting Process Technicians in troubleshooting in the event of a problem
  • Data collection, interpretation and report writing
  • Planning and installation of new equipment
  • Risk assessments of the equipment and processes being used. Of course, this refers to staff safety and safety within the plant, but this can also extend outwards to include things such as the environmental impact
  • Continual evaluation of equipment and processes to ensure both efficiency and quality remain high
  • Budget responsibilities
  • Trains machine operators on new equipment installations, modifications, and new operating procedures.
  • Maintains standard operating conditions system which ensures consistent manufacturing equipment processing conditions.
  • Works with plant BPI resources to ensure technical support resources are available to production at all times.
  • Works with manufacturing supervisors, production crews, and maintenance to troubleshoot manufacturing problems and develop corrective actions to eliminate the return of those problems
  • Participates in the evaluation of projects and waivers to aid in the effective scheduling and necessary product development coverage to minimize the risk of machine downtime and high waste due to developmental efforts in manufacturing.
  • Works with plant project engineering to facilitate equipment modifications to increase machine productivity and reduce waste.
  • Initiates and documents procedures to safely increase machine productivity and reduce waste while maintaining product quality per customer expectations.
  • Participates in the training of machine operators on new equipment installations, equipment modifications and new operating procedures.
  • May provide supervision to engineering co-op students depending on experience and workload, including performance evaluations, training and directing activities



Essential Qualifications & Experience

Strong interpersonal and communication skills, both oral and written, to work with manufacturing operations personnel.

Must have strong analytical and problem-solving skills.

General knowledge of flexible packaging products, including the desired properties and quality standards for those products.

Must have strong time management skills to handle multiple ongoing projects in addition to day to day process problems.

Solid computer skills including Microsoft Word and Excel, Outlook, Share Point, and the ability to quickly learn software needed to perform job specific duties.

Strong knowledge of process used to manufacture and convert flexible packaging. Especially blown film, metallization, flexographic printing, extrusion coating, adhesive laminating, and slitting/winding operations.

Ability to work independently with minimal supervision

Interpret technical drawings – especially process flow diagrams, piping and instrumentation diagrams (P&IDs) and pipe skids

Project management – have to ability to manage people, budgets and complex projects and bring them to completion on time and on budget

Spatial reasoning – the ability to see a two or three-dimensional object and then mentally manipulate it

Critical/logical thinking – have to locate problems, and then think of those problems from a variety of perspectives to assess the best solution

Excellent communication skills – working with people across the manufacturing process, they have to be able to manage people well and communicate new ideas effectively

Calm under pressure – must be able to troubleshoot at an advanced level. If a problem is delaying manufacturing, they must be able to come up with effective working solutions quickly

Commercial awareness – usually working within strict time and budgetary constraints

Excellent computer skills – IT is an essential part of this role, uses include simulation software, design software and reporting

Analytical skills – responsible for analysis and interpretation of data into charts, diagrams, and reports

Negotiation skills – vital if charged with budgetary or schedule management

Creative thinking and excellent problem-solving skills – have to be able to solve problems in a new way, seeing past what is established and create a new way of doing things

Bachelor’s Degree in Engineering with a minimum of 10 years of hands-on engineering work experience

Experience applying structured problem solving approach (such as 8D, 8-Step, DMAIC or PDCA) that drives root cause analysis using 5-Why, Why Trees, and Fishbone analysis

Ability to apply engineering fundamentals and statistical tools to development, optimization, and troubleshooting activities

Ability to prioritize, plan, and drive multiple projects concurrently from development to completion against agreed upon timelines and deliverables

Ability to work independently and collaborate effectively as part of a team, including influencing across functions

Ability to identify critical issues and failure modes, creating a framework of action to address these issues and assess root cause including effective risk-based decision making

Ability to document, communicate, and present technical bodies of work

Ability to travel up to 30%

US work authorization (Required)

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