Process Engineer

Description

Job title: Process Engineer

Reports to: Site General Manager

 Direct reports: n/a

 Back up position: Manufacturing Manager

 Department: 0400 - Extruded Production

 Work location: Evansville, IN

 Exempt/Non-Exempt: Exempt

 Job Description date:  1/17/25

I - Job Purpose and Summary:

Responsible for providing hands on process knowledge, technical advice, continuous improvement, support, guidance, and training on all matters relating to the entire process with a focus on the extrusion process. Support development and commercialization of new products (NPD) along with the improvement and line to line transitions of existing products.  Work alongside the Capex engineering team to support and/or lead agreed Capex projects. Continuously improve the entire process, including the extrusion process, to enhance the balanced scorecard - HSE, Quality, Efficiency, Cost, and People. 

Requirements

II - Key Accountabilities: 

1. HSE: Promote a safe work environment at   all times through the adherence to all PGP’s Health, Safety and Environmental   policies and procedures as well as to all relevant regulations in order to achieve ZERO   workplace incidents and injuries. The   process engineer will contribute to HSE continuous improvements and process   related HSE projects.

2. Food Safety &   Quality: Ensure   compliance with rigorous standards of food safety, quality, legality, and   authenticity, playing a crucial role in maintaining the highest standards   throughout the entire food production process. The process engineer will contribute to the   maintenance and improvement of the food safety and quality of the products   and will be engaged in process related food safety and quality projects. Support investigations and corrective   actions for any quality deviations and/or customer complaints. Monitor our master sample program and   ensure the extrusion processes are producing product aligned with the   customers’ requirements specifications, and master samples.

3. Production Activities: Support the day-to-day   operation by providing technical and engineering assistance to the production   team in an effort to maximize production line efficiencies and KPIs. Lead and manage continuous improvement   projects related to the entire process including extrusion. This may include leading capex projects   that are related to the process, equipment, and the extruders. The process engineer will participate in   the development and commercialization of new products alongside our Innovation   team along with the improvement and development of existing products (EPD)  and line to line product transitions. This   will necessitate organizing, over-seeing/running trials and scale-up runs on   a regular basis. Assess inbound materials for key characteristics / consistency   and assess potential ingredient (and/or product) modifications, actively   consulting with all stakeholders in a timely and effective manner - including   Procurement, Sales, Vendors, QA, CQFS, etc., to determine the best outcome.   Investigate equipment / process / material problems, devise methods of repair   or correction, and adjust. Conduct mass balance exercises associated with   commercial production and Innovation and EPD trials.

4. Maintenance: Ensure process and extrusion equipment such as dies,  elements, barrels are regularly inspected, measured, documented, inventoried   and a plan in place to PM and replace as needed. Modification of equipment as   needed and/or requested for continuous improvement. Responsible for maintaining   inventory of extruder wear parts and recommending when to replace and/or   rebuild. Work with die machine shop on   die design, drawings, and new and replacement die requests. The process engineer may lead Capex   projects with the support of the Engineering team for process equipment   upgrade and/or replacement projects.

5. Record Management: Consult and collaborate with relevant   stakeholders, develop, and embed a methodology whereby all extrusion   equipment, processes SOP’s, set-up’s, modifications, corrective actions,  trials, etc. are clearly and routinely documented, reviewed, updated, and   referenced. Ensuring accurate inventory records of all extrusion parts and   measurements. Report findings and recommendations to Management and Senior   management, as needed. Monitor and update MPF’s on a regular basis to ensure information   is correct and up to date. Coordinate information between Innovation, CQFS,  QA and Operations department (equipment details, parameters, settings, feed   rate, etc.) to maintain high quality for customer satisfaction and   consistency. 

6. Problem Solving /   Reporting / Continuous Improvement: Work with managers, leads and operators to develop   and deploy process improvement solutions including operating procedural   changes, line modifications and any other changes (e.g., raw materials) to   ensure that improvements are consistent and sustained. Support day-to-day   extrusion operations in problem solving activities. Work closely with the Management   team and Innovation Group to apply appropriate techniques (RCA, etc.),  understand and seek to eliminate sources of non-conformances and quality   deviations. Through the analysis of process control data, production records   and product specifications, ensure the consistent and effective application   of extrusion equipment, tools, and process control instrumentation/controls,   developing improvements where appropriate. 

7. Training &   Development: Participate   in all trainings related to job to gain knowledge / skills / abilities needed   for exceptional performance. Develop and effect the provision of process and   extrusion training material and techniques to support the on-going personal   development of Process Operators / Technicians and Leaders in the use of   extrusion equipment and the entire production line and the understanding of   the relationship between raw materials and process.

III - Internal and External Contacts: 

Internal

All employees in Operations,  Maintenance, Logistics, Innovation, Quality, Engineering and HSE departments. 

External

Equipment   suppliers based on needs

IV - Job Requirements (Required and Preferred):

Education 

· BS in Engineering (mechanical, chemical, etc.),   Engineering Technology, or Food/Material Science - or other relevant   qualification (specific exposure to Extrusion Technology would be   particularly advantageous) - or equivalent experience (desirable)

Related   Experience

· Minimum 3 years of process engineering   experience with demonstrated improvement projects

· Manufacturing experience in extrusion   of food and food ingredients is ideal but not required 

· Expert knowledge of manufacturing   equipment (i.e. extruders, dryers, dry powder handling systems, packaging   systems, etc.)

· Project Management including   project development, implementation, and review.

· Mechanical and Maintenance   experience

Competencies

· Driving For Results, Priority   Setting, Problem Solving, Planning, Hands on and proactive, Process   Management, Compelling Communication, Comfortable to challenge Senior Leadership, Listening, Conflict Management, Understanding Others, Organizational Agility, Operational Decision Making, Dealing with Ambiguity, Business Acumen, Ownership, Driving Innovation, Continuous Learning, Self-Knowledge, Building Trusted   Relationships

Technical   Skills

· ERP transactions, touch screen   tablets/PLC, advanced math skills, use of pneumatic and small hand tools, Lock   out tag out (LOTO) system, confined space entry experience.

· Engineering and problem solving skills

· Manufacturing equipment   knowledge (i.e. extruders, dryers, dry powder handling systems, packaging   systems, etc.)

Certifications,  Licenses, Registrations

· None required 

Language(s)

· Fluency in English - required

· Fluency in Spanish – would be a bonus

Other   Qualifications

· HACCP, Good Manufacturing   Practice (GMP), or any food safety related qualifications ideal but not   required

 V – Work/Employment Conditions and Other Requirements: 

Work   Environment

This job operates   in a manufacturing warehouse environment. This role routinely uses   manufacturing equipment. The environment is hot, cold, wet, dusty, and loud.   Must be able to don personal protective equipment on the manufacturing floor   (hearing protection, hard hat, safety glasses, beard/hair nets, safety   shoes). This role will be exposed to allergens including gluten &   soy. This role will be exposed to Neodymium magnets.

Physical   and Sensory Demands

While performing   the duties of this job, the employee is required to stand; walk; use hands to   handle, or feel objects, tools or controls; reach with hands and arms   overhead and grip; climb stairs, work from heights up to 40 feet; talk or   hear. The employee must occasionally lift or move products and supplies, up   to 55 pounds.

Position   Type and Working Schedule

RFT - Regular   Full Time, working schedule based on production demands

Travel   Requirements

Occasional travel PGP's site in Woodland, CA; equipment suppliers for factory acceptance tests, and technical conferences related to food processing equipment and/or food science technologies.

VI - Other Duties: 

Please   note this job description is not designed to cover or contain a comprehensive   listing of activities, duties or responsibilities that are required of the   employee for this job. Duties, responsibilities, and activities may change at   any time with or without notice.