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E-glass Process Engineer

2 months ago

Gadsden, Alabama, United States Johns Manville Full time

Company Overview

Johns Manville stands as a premier producer and distributor of high-quality insulation and commercial roofing solutions, alongside glass fibers and nonwovens tailored for various applications in commercial, industrial, and residential sectors. Our offerings find utility across diverse industries such as building materials, aerospace, automotive, transportation, filtration, commercial interiors, waterproofing, and renewable energy.

As a proud member of the Berkshire Hathaway family, we cater to clients in over 80 countries worldwide. Our commitment lies in fostering positive and impactful experiences, as our success is intertwined with the prosperity of our employees and customers. We are driven by passion, care for individuals, superior performance, and environmental stewardship.

Compensation

The anticipated salary range for this position is $108,100.00 to $148,600.00 annually. This range reflects the base salary that candidates can expect upon hiring, with variations based on relevant experience, skills, and educational background. Additionally, this role is eligible for an incentive bonus.

Role Summary:

The Senior Process Engineer is tasked with providing technical leadership for the operation of E-glass furnaces at our facility, focusing on optimizing output, material usage, and energy consumption while adhering to product specifications. Achieving these objectives necessitates the establishment of robust data collection processes, auditing, and preventive maintenance to swiftly identify deviations and implement corrective actions. Methodologies such as RCCA analysis, 5 Whys, and the JM Solve-It approach or Keppner/Tregoe, along with a Six Sigma framework, will be employed as necessary. Furthermore, the Senior Process Engineer will spearhead initiatives aimed at enhancing process efficiency, product quality, and reducing costs associated with poor quality, thereby leading process optimization efforts.

Collaboration with electrical engineers will be essential to develop and refine process control architectures. In partnership with specialists at JMTC, process modeling systems will be created and implemented to further enhance operational efficiency. Regular reviews of raw material specifications will be conducted based on performance analyses to drive anticipated improvements.

Daily Responsibilities:

  • Conduct ongoing analyses to identify areas for enhancement and corrective measures.
  • Develop improved control processes and new operational procedures.
  • Define process set points for various product types and create corresponding management tools (e.g., setup sheets in MII, SOPs).
  • Actively promote safety performance improvements by encouraging safe practices among team members and engaging in initiatives to enhance the safety culture.
  • Stay abreast of the latest technologies and assess their applicability to current and future processes.
  • Collaborate with internal and external resources to explore new opportunities, mentoring and developing process engineers within the division, and sharing insights proactively within the broader technical community.
  • Work across multiple locations and functions to identify process improvement opportunities, addressing aspects such as inventory levels and labor requirements.
  • Provide leadership for process redesign initiatives during rebuilds or significant investment projects across divisions.
  • Lead multiple projects and process optimization efforts within a manufacturing context, potentially spanning divisions.
  • Offer technical guidance throughout development, construction, and startup phases to enhance in-plant resource capabilities.
  • Perform other related duties as assigned.

Qualifications:

  • Bachelor's degree in engineering or a related field, with a minimum of 5 years of experience in continuous industrial process manufacturing, either as a process or design engineer, and at least 2 years of troubleshooting experience.
  • Proven success in identifying and implementing process improvements.
  • Strong problem-solving abilities, including complex data analysis.
  • A history of innovation and adaptability.
  • Excellent project management capabilities.
  • Demonstrated ability to manage multiple projects effectively and prioritize tasks.
  • Results-oriented, with a track record of leading key projects to successful outcomes.
  • Experience with complex Design of Experiments (DOE) for process enhancement.
  • Strong interpersonal, verbal, and written communication skills.
  • Ability to work independently and collaboratively within a team environment.
  • Skill in setting and communicating expectations to team members.
  • Proven collaboration skills, with the ability to engage with a diverse range of employees and disciplines, including finance, procurement, and project engineering.
  • Capacity to make timely decisions.
  • Proficiency in Microsoft Word, Excel, PowerPoint, and Outlook.
  • Strong leadership capabilities.
  • Proven analytical skills and a commitment to quality improvement.
  • Ability to interface effectively at all organizational levels, both internally and externally.
  • Experience supervising or leading individuals or project teams to achieve milestones and objectives through priority setting and direction.
  • Familiarity with E-glass melter operations or equivalent processes.
  • Experience with combustion systems in melters/forehearths.
  • Knowledge of refractory maintenance and hot repairs.
  • Understanding of melter pollution control systems.
  • Proficient in using process data historians.

Preferred Experience:

  • Familiarity with glass leak procedures.
  • Experience with Honeywell DCS systems.

Additional Information:

Candidates should be aware that reasonable accommodations may be made to enable individuals with disabilities to perform essential job functions. We are an Equal Opportunity/Affirmative Action employer and maintain a drug-free workplace, conducting pre-employment substance abuse testing.