Production Engineer

General Responsibilities: Monitoring : Closely monitor day-to-day plant operations. Monitor yield, costs, downtime, productivity, WIP and quality for the assigned production process. Monitor whatever is necessary to effectively manage and optimize the production process. Develop and track daily, weekly and monthly yields and production for each step versus standards. Develop a nearly real-time database of key operating data for each step for use in process optimization. Report daily production, yield, and downtime for each step in the assigned production process in order to better optimize production, costs and quality. Regularly attend pre-shift brief Monitor quality of all raw materials, WIP and production Scheduling : Assure the production schedule is met through the scheduling of raw materials, trouble shooting production and process issues, timely maintenance of the production equipment and proper direction. Ensure the operators are given timely and clear instructions as to operating schedules, WIP blends, etc. Manage downtime, shutdowns and maintenance to maximize productivity. Integrate product forecast with equipment utilization. Ensure all necessary supplies are on-hand to achieve our production and cost goals Provide timely disposition and movements of raw materials, in process and finished product. Perform level-loading on unit operations to avoid swings in WIP build and ensure smooth operation between Manufacturing, Packaging, and sales demand Cost Reduction : Aggressively work to reduce operating costs by reducing downtime, increasing productivity, increasing yields and reducing raw material costs in the assigned production process. Identify and support the implementation of process improvements. Optimization of batch reaction and distillation unit operations. Assess and optimize workflows and utilization (both personnel and equipment) Process & Production Supervision : Plans, directs and coordinates to ensure that production meets output and quality goals while remaining in budget Trouble-shoot production and process issues Works with supervisors, operators and maintenance personnel to solve process problems and advise corrective actions as needed; Resolves operational, manufacturing, and maintenance problems to ensure minimum costs and prevent operational delays Provide direction and training as required. Issue daily notes as necessary to communicate in a clear and timely fashion, current operating conditions and materials usage instructions to the floor operating personnel. Work on increasing capacity of the assigned unit Maintain up-to-date process related documentation (development of standard work instructions; SOPs, validation protocols, technical instructions, etc.). Participating in the development of standard work instructions; Safety : Ensure the process is operated in a safe fashion. Our goal is zero safety incidents or accidents. Implement, adhere to and insure proper change management procedures are followed. Evaluate, understand and communicate all pertinent safety issues and hazards associated with each assigned process step. Ensure all operating and maintenance personnel are following all safety guidelines and procedures. Initiate and implement safety related projects. Participate in PHA in assigned production process. Insure a safety review is completed for new project (minor or major) or process change in assigned production process. Initiate and complete projects to ensure redundant safety interlocks exist for all potential hazards Continuously improve current state by assessing need for interlocks, bypasses, etc., and resolve with automation and operations personnel Health : Ensure company standards & regulatory requirements are met with respect to chemical exposures in your assigned production process Insure all personnel use PPE appropriate for task they are performing Working with EH&S, insure PEL compliance for all personnel and areas Initiate and complete projects to reduce operator contact with chemicals Environment : Ensure company standards & regulatory requirements are met with respect to air, waste and water compliance in your assigned production process Working with EH&S, insure RCRA, waste water and air compliance Initiate and complete projects to reduce waste disposal costs Achieve a goal of zero environmental emissions or incidents in their assigned area Quality : Monitor quality of all raw materials, WIP and production to insure Participate in quality investigations, including process deviations and customer complaints. Manage CAPAs related to quality investigations, especially long-term preventative actions Perform process-related discrepancy investigations as required. Work with the Quality Manager to insure proper scheduling of samples to meet production goals. Develop and execute validation protocols for changes that impact the filed manufacturing process Projects : Initiates, manages and completes projects in their assigned areas as well as other assigned projects to support production and process improvements. Conceive, conceptualize, design, develop, manage and implement capital and other projects in their assigned areas to increase capacity, reduce costs and achieve other production, cost, yield, safety, quality, and environmental goals. Manage a variety of replacement-in-kind and other maintenance projects Manage a team of personnel for each project, ensuring timelines and budget are met Other Duties Assist in annual budget preparation, the development of cost standards and other capital forecasts Support requests from Regulatory Affairs related to the Bethlehem operations Assist in the validation of equipment and process changes Help lead new process roll-outs in the department, such as tools, methodologies, corporate initiatives, etc. Support cultural initiatives for the site Conduct other tasks as required