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Key Responsibilities and Required Skills for Process Engineer

💰 $75,000 - $130,000

EngineeringManufacturingOperationsChemical EngineeringIndustrial Engineering

🎯 Role Definition

Are you a results-driven engineer with a passion for optimization and a talent for complex problem-solving? This role requires a highly motivated and analytical Process Engineer to join our innovative team. In this pivotal role, you will be the cornerstone of our operational excellence, responsible for designing, implementing, and refining the processes that drive our production. You will work hands-on to improve efficiency, ensure quality, maintain safety, and reduce costs across our manufacturing landscape. This position offers a unique opportunity to make a significant impact on our products and our bottom line, working cross-functionally with R&D, Quality, and Operations to bring concepts to reality. If you thrive in a dynamic environment and are eager to apply your engineering expertise to tangible challenges, we want to hear from you.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Junior Process Engineer or Process Engineer I
  • Chemical, Mechanical, or Industrial Engineering Graduate
  • Manufacturing Engineer or Production Engineer

Advancement To:

  • Senior Process Engineer / Lead Process Engineer
  • Engineering Manager / Plant Engineering Manager
  • Operations Manager or Plant Manager

Lateral Moves:

  • Project Manager / Engineering Project Manager
  • Quality Assurance Engineer / Manager
  • Continuous Improvement Manager

Core Responsibilities

Primary Functions

  • Design, develop, and implement new manufacturing processes, including conducting process simulations and scaling up from pilot to full production.
  • Lead continuous improvement initiatives using methodologies like Lean Manufacturing, Six Sigma, and Kaizen to enhance production efficiency, reduce waste, and lower operational costs.
  • Develop and maintain comprehensive process documentation, including Process Flow Diagrams (PFDs), Piping and Instrumentation Diagrams (P&IDs), Standard Operating Procedures (SOPs), and work instructions.
  • Monitor, analyze, and optimize existing processes by collecting and interpreting production data, utilizing Statistical Process Control (SPC) to ensure consistency and identify areas for improvement.
  • Troubleshoot complex production and process problems in real-time, providing technical support and guidance to operations teams to minimize downtime and resolve quality issues.
  • Manage capital improvement projects from conception to commissioning, including defining project scope, developing budgets, specifying equipment, and overseeing installation and validation.
  • Ensure all processes and equipment comply with environmental, health, and safety (EHS) regulations, leading Process Hazard Analyses (PHAs) and participating in safety audits.
  • Collaborate with the Research & Development team to facilitate the seamless transition of new products from the lab to full-scale manufacturing, ensuring manufacturability and cost-effectiveness.
  • Qualify and validate new equipment, materials, and process changes, executing validation protocols (IQ/OQ/PQ) to meet internal quality standards and regulatory requirements.
  • Develop and justify capital expenditure requests for new equipment and process upgrades by conducting cost-benefit analyses and presenting business cases to senior management.
  • Provide technical training to production operators and maintenance technicians on new processes, equipment operation, and safety procedures.
  • Identify and implement automation opportunities to improve process control, reduce manual intervention, and increase overall equipment effectiveness (OEE).
  • Conduct root cause analysis (RCA) for process deviations, product non-conformances, and safety incidents, implementing robust corrective and preventive actions (CAPAs).
  • Lead and participate in cross-functional teams to address systemic operational challenges and drive strategic site-level improvements.
  • Evaluate and select new manufacturing technologies and equipment vendors to maintain a competitive advantage and enhance process capabilities.
  • Establish key performance indicators (KPIs) for process performance, such as yield, throughput, cycle time, and uptime, and create dashboards for ongoing monitoring.
  • Perform capacity analysis and production planning to ensure manufacturing capabilities can meet current and future market demand.
  • Manage changes to processes and equipment through a formal Management of Change (MOC) system to ensure safety and control.
  • Author and execute experimental test plans (e.g., Design of Experiments - DOE) to characterize process windows and optimize critical process parameters.
  • Support the supply chain by qualifying alternative raw material suppliers and optimizing material usage to reduce costs and mitigate supply risks.

Secondary Functions

  • Support ad-hoc data requests and exploratory data analysis to inform business decisions.
  • Contribute to the organization's long-term technology and process strategy roadmap.
  • Collaborate with business units to translate product and quality needs into engineering requirements.
  • Participate in sprint planning, daily stand-ups, and other agile ceremonies within project teams.
  • Assist the maintenance department in developing preventive maintenance plans for critical process equipment.
  • Mentor junior engineers and interns, providing guidance on technical challenges and professional development.

Required Skills & Competencies

Hard Skills (Technical)

  • Process Optimization: Mastery of continuous improvement methodologies such as Six Sigma (Green or Black Belt preferred) and Lean Manufacturing principles.
  • Process Simulation Software: Proficiency with tools like Aspen HYSYS, Aspen Plus, ChemCAD, or similar simulation packages.
  • CAD & Engineering Drawings: Ability to read, create, and modify P&IDs, PFDs, and equipment layouts using software like AutoCAD or SolidWorks.
  • Statistical Analysis: Strong experience with Statistical Process Control (SPC) and data analysis software (e.g., Minitab, JMP, R).
  • Project Management: Demonstrated ability to manage capital projects, including scoping, budgeting, scheduling, and execution.
  • Root Cause Analysis (RCA): Expertise in structured problem-solving techniques like 5 Whys, Fishbone Diagrams, and Fault Tree Analysis.
  • Process Safety Management (PSM): In-depth knowledge of EHS regulations and experience leading safety reviews like HAZOP and FMEA.
  • Validation Protocols (IQ/OQ/PQ): Experience in writing and executing validation plans for equipment and processes, particularly in regulated industries (pharma, medical devices).
  • Automation & Control Systems: Familiarity with PLC, HMI, and SCADA systems and an understanding of process control loops.
  • Data Historian & Analysis: Experience using data historians like OSIsoft PI System to analyze process trends and troubleshoot issues.

Soft Skills

  • Analytical Problem-Solving: A systematic, data-driven approach to identifying, analyzing, and resolving complex technical problems.
  • Effective Communication: Ability to clearly convey complex technical information to diverse audiences, from shop floor operators to senior leadership, both verbally and in writing.
  • Collaboration & Teamwork: Proven track record of working effectively in cross-functional teams to achieve common goals.
  • Leadership & Influence: Capacity to lead projects and influence stakeholders without direct authority to drive change and improvement.
  • Attention to Detail: Meticulous and thorough in documentation, analysis, and execution to ensure process integrity and quality.
  • Adaptability & Resilience: Thrives in a fast-paced, dynamic environment and can effectively manage multiple priorities and shifting deadlines.
  • Innovative Mindset: Proactively seeks out new technologies and creative solutions to improve processes and challenge the status quo.

Education & Experience

Educational Background

Minimum Education:

  • Bachelor of Science (B.S.) degree in an engineering discipline.

Preferred Education:

  • Master of Science (M.S.) in Engineering.
  • Certifications such as Six Sigma Black Belt, Professional Engineer (PE), or Project Management Professional (PMP).

Relevant Fields of Study:

  • Chemical Engineering
  • Mechanical Engineering
  • Industrial Engineering
  • Manufacturing Engineering

Experience Requirements

Typical Experience Range: 3-7 years of hands-on process engineering experience in a relevant manufacturing environment.

Preferred:

  • Experience in industries such as chemical processing, pharmaceuticals, semiconductors, food and beverage, or consumer packaged goods.
  • Proven success in leading significant process improvement or capital projects from concept through completion.
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