Plant/Production Engineer

Job Description

This position works closely with the Operations team, including shift teams, supervisors, production managers, and Operations Managers, to drive process optimization and continuous improvement across formulation and related units within the production plant. It also collaborates with maintenance, quality control, and other supply chain functions. As the role evolves, the individual will become the process owner and subject matter expert for assigned areas, such as formulation vessels and packaging lines. Key responsibilities include daily performance assessments of process units (yield, throughput, quality), investigating and implementing corrective actions for quality and safety incidents, and ensuring adherence to Company’s safety and quality standards. Additionally, the role will lead or support continuous improvement initiatives aimed at enhancing safety, quality, efficiency, cost-effectiveness, new product introduction, and the design and commissioning of new equipment in the plant.

Responsibilities will include:

• Lead by example in promoting safety programs and ensuring adherence to safety policies.
• Monitor and close audit actions related to assigned areas of responsibility.
• Initiate, manage, and close MOC (Management of Change) actions in line with assigned responsibilities.
• Minimize production variances, focusing on material usage, yield, and write-offs.
• Measure and improve Overall Equipment Effectiveness (OEE) to optimize plant performance.
• Implement Statistical Process Controls (SPC) in key areas to enhance safety, quality, production efficiency, and cost control.
• Regularly update Bill of Materials (BOM) in Oracle, reduce scrap factors, and refine production routings.
• Collaborate closely with the Production Coordinator, Production Manager, Supervisors, and Production Scheduler to improve adherence to production plans over the next 12 months.
• Actively participate in Rough Cut Capacity Planning meetings to ensure successful production planning and on-time customer delivery.
• Lead Apollo-certified root cause investigations and ensure timely closure of actions within assigned areas of responsibility, while implementing sustainable corrective actions for identified issues.
• Ensure procedures and checklists are consistently maintained, updated, and properly utilized.
• Work with the Operations team to troubleshoot and resolve safety, quality, and production challenges.
• Document best practices, lessons learned, corrective actions, and preventive actions within the plant's Standard Operating Procedures (SOPs).
• Ensure Unusual Incident Reports (UIRs) are logged, investigated, and actions are appropriately closed.
• Support Operations and Packaging Managers in cost management and driving cost reduction initiatives.
• Facilitate new product introductions and ensure the timely, safe, and cost-effective production of new campaigns, meeting quality standards.
• Conduct site tours for customers and collaborate with the Quality team to reduce quality complaints.
• Ensure compliance with Company’s Product Integrity Golden Rules and safeguard against product contamination in assigned areas.
• Act as a subject matter expert in compliance with CropLife’s requirements.
• Support capital expenditure (CapEx) projects by defining scope, managing construction, writing and implementing procedures, training plant personnel, and overseeing successful operational handover.
• Provide backup for the Process Control Engineer, troubleshooting code and logic issues to ensure smooth operations without force or alarm nuisance.
• Train or assist in training plant personnel on all aspects of packaging operations, including safety, product contamination, quality, and production best practices.

Process Performance – Routine measurement and assessment of process performance for assigned formulation vessel (reactor), storage, and packaging lines or areas.  Focus on providing training, procedures, corrective actions, and tools (5S, Root Cause Analysis, etc.) for achieving cycle time and yield targets.

Process Improvement Projects – Identify, lead, or support projects that optimize performance metrics and achieve plant goals.  These may include work-process design and implementation, equipment procurement and implementation, software implementation, training, SOP development.

Quality – Work with Quality personnel to ensure and support appropriate procedures, training, tools, incident investigations, and metrics are in place to conform to Company quality and contamination prevention standards for assigned units.  Drive improvement in key Quality metrics such as right-first time and non-conforming products.

Safety, Health, and Environmental – Work with HSE personnel to ensure and support appropriate procedures, training, tools, incident investigations, and metrics are in place to conform to Company standards for assigned units.  Support waste reduction

New Product Introduction – Support introduction of new or modified products to assigned process units.  Participate in transfer-to-manufacturing process. 

Qualifications

Mandatory:

• Bachelor’s degree in chemical engineering or equivalent experience
• Minimum of 5 years in manufacturing, process, or quality engineering.
• Identify, drive, and implement key process and equipment improvements in collaboration with plant management, quality, safety, supervisors, maintenance, engineering, and operators.
• Identify root causes, implement corrective actions, and troubleshoot issues to enhance process efficiency.
• Exhibit personal energy and adaptability in a fast-paced, dynamic, and growing organization. This role requires significant time working in the plant as well as desk activities.
• Strong technical report writing and oral communication skills.
• Proficiency with chemical processing equipment and MS Office Suites.

Desirable:

• Experience with Six Sigma, Lean, SPC, Root Cause Analysis, and 5S.
• Experience with MRP/ERP, database programming, SPC software, and/or manufacturing control systems (MES, PLC)
• Experience in batch chemical manufacturing.
• Experience with Process Safety Management
• Experience with Project Management
• Experience with MS SharePoint and PowerBI

Why is This a Great Opportunity

Global Agri-Chemicals company offering excellent compensation and continued career growth opportunity. 

We are an emerging recruitment organization working with well-known clients based in the USA. Our services offer a wide range of functions related to recruitment. Our young yet experienced team strives to offer the best services to our clients. 

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