Production Optimization Engineer
1 week ago
Position Summary:
The Manufacturing Engineer plays a crucial role in ensuring the safe, reliable, and efficient operation of production units. This position is responsible for monitoring and enhancing unit performance, which encompasses production metrics, material consumption, energy efficiency, quality assurance, daily performance evaluations, troubleshooting, and basic optimization of manufacturing processes.
Key Objectives:
- Become a subject matter expert in the designated manufacturing unit.
- Gain a comprehensive understanding of the unit's control strategies, including alarm systems.
- Identify improvement opportunities and formulate strategies to enhance operational performance.
- Build collaborative relationships across the organization to influence performance outcomes.
Main Responsibilities:
- Champion a zero-incident safety culture through proactive safety practices and employee engagement.
- Foster strong working relationships with Operations, Manufacturing, Process Engineering, Quality Assurance, and other support teams.
- Design and implement best-in-class processes based on lean and Six Sigma methodologies to achieve safety, compliance, cost efficiency, and quality goals.
- Encourage a culture of continuous improvement by actively participating in cross-functional teams.
- Oversee the development and maintenance of a robust pipeline of Six Sigma projects aimed at enhancing safety, quality, and productivity.
- Ensure adherence to Key Performance Indicators (KPIs) and budgetary commitments.
- Optimize inventory management by aligning production plans with sales order requirements.
- Serve as a technical resource for key processes, including Process Hazard Analysis (PHA), Layer of Protection Analysis (LOPA), and Failure Mode Effect Analysis (FMEA).
- Lead Management of Change (MOC) initiatives and conduct Root Cause Analysis (RCA) to improve safety and performance.
- Guarantee consistent compliance with quality standards and address root causes of customer complaints.
- Coordinate with Operations and Maintenance teams to safely and efficiently manage scheduled outages.
- Collaborate with the Site Engineering team to develop cost-effective capital projects that align with KPI objectives.
- Support the execution of technology programs that deliver innovative solutions for performance enhancement.
Team Structure:
Reports to the Production Manager.
Qualifications:
- Bachelor's degree in Chemical Engineering.
- A minimum of three years of experience in chemical manufacturing.
- Proven ability to work effectively within a self-directed team environment.
- Strong commitment to safety, environmental, and industrial hygiene practices.
- Excellent verbal and written communication skills.
- Proficient in Microsoft Office, SAP, and Minitab.
- Ability to simplify complex technical issues for upper management.
- Experience in coaching and mentoring other engineers.
- Strong organizational and time management skills.
- Familiarity with Process Flow Diagrams and P&IDs.
- Capability to generate heat and material balances.
- Understanding of basic accounting and plant cost economics.
- Proactive leadership and team-building skills in a fast-paced environment.
- Strong sense of ownership and a drive for continuous improvement.
Required Skills:
- Certification in Six Sigma (Yellow Belt, Green Belt, or Black Belt).
- Knowledge of Process Safety Management (PSM), Title V, and ISO 9001 standards.
- Familiarity with Provox/DeltaV DCS systems.
- Understanding of quality systems and their operational consistency.
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