Senior Process Engineer

As the Senior Process Engineer, you will Plan and develop manufacturing processes and method systems in whole, or in part, to meet stated objectives. You will also have the opportunity to lead projects or portions of projects; provide support and guidance for colleagues in other departments.

Major Responsibilities

• Maintain up to date on manufacturing activities through daily reviews of production records, historical trends, quality results and site communications. Provide support to all site manufacturing areas as needed through collaborative efforts to troubleshoot and correct operational and quality deficiencies. As needed, participate or lead Root Cause Analysis (RCA) investigations aimed at eliminating repeat failures. Routinely monitor historical material property performance to identify negative (or positive) trends and report findings to Engineering Manager.

• Drive continuous improvement through execution of medium to large projects or initiatives assigned by Engineering Manager. Interface with multiple disciplines to determine requirements and constraints. Develop business case, technical solution(s), deliverables, execution plan and performance metrics. Drive project forward to meet all deliverables. Provide technical support on matters within your discipline. Document and report progress, challenges and needs. Routinely report progress to all stake holders. Ensure successful execution and close out of changes.

• Identify and investigate events that causes production downtime. Utilize production data and collaborate with other departments to identify process or equipment deficiencies. Use findings to drive deeper investigations, projects or corrective actions targeted at reducing production outages.

• Evaluate documented or historical equipment entitlement information to determine if equipment is underperforming, resulting in loss of capacity. Participate in or lead multi disciplinary investigations to identify the root causes for capacity loss and implement potential corrective actions. Alternatively, if equipment is not reaching its entitlements due to intentional reasons, lead investigations to identify if there is opportunity to gain additional capacity.

• Update documented operating procedures as required as part of Management of Change process for projects in which you are involved. Use process knowledge and Operation's feedback to improve established processes as needed.

• Act as site subject matter expert (SME) for assigned equipment and manufacturing systems. Direct Operations and/or Reliability in matters relating to this equipment. Develop and implement best practices and drive continuous improvement for the site on assigned systems.

• Participate or lead investigative production trials by identifying potential areas of concern, determining required changes to processing conditions or preparing special reports or guidelines. During trials, monitor the production process, make necessary adjustments or document any important events, document all relevant processing and quality information and present it to trial author.

• Participate or lead projects aimed at implementing new methods/technologies in support of site digitalization and sustainability efforts

• Responsible for the development and management of all site production operating parameters.

• Support the sites "safety first" culture in all aspects of the role. Consult with HSEQ, reliability and other Sr. Engineers to ensure that all regulatory and Covestro mandated safety requirements are met for materials, processes and equipment.

• Facilitate the transfer of products to the Newark site from other production facilities. Contact the appropriate Production Specialist/Process Engineer at the originating plant(s) to collect relevant information on how the material was processed and any concerns/difficulties that there have been with the product. Establish and document operating parameters, noting all special considerations and requirements.

• Assist global compounding technology group in development of best practices.

Basic Qualifications

• High school diploma or equivalent and a minimum of 15 years of manufacturing experience OR

• Associates degree and a minimum of 10 years of manufacturing experience OR

• Bachelor's degree in Chemical or Mechanical Engineering or related degree and a minimum of 5 years of manufacturing experience OR

• Master's degree in Chemical or Mechanical Engineering or related degree and a minimum of 3 years of manufacturing experience OR

• PhD in Chemical or Mechanical Engineering or related degree and a minimum of 1 year of manufacturing experience

Preferred Qualifications

• Ability to query data using SQL, experience with HTML and/or TypeScript, or experience using Angular to build web applications.

Knowledge & Skills:

• Strong interpersonal skills and ability to engage and interact across all levels of the organization.

• Proven ability to successfully manage multiple projects and priorities.

• High level of organizational and process/project management skills.

• Demonstrated ability to be proactive and self-reliant. Curious and passionate about expanding knowledge and capabilities.

• Proven excellent written and verbal communication skills.

• Experience participating in or leading Root Cause Analysis investigations.

• Familiar with Lean Six Sigma methodologies and tools.

• Demonstrated excellent analytical and problem-solving skills, ability to apply rigorous logic.

• Proven ability to analyze large data set from multiple sources and develop technical reports summarizing results.

• Familiar with basic statistical analysis tools.

• Preferred previous experience developing 2D drawings in AutoCAD or similar software.

• Familiar with process controls and HMI interfaces.

• Experience as technical support for manufacturing process. Preferred Thermoplastic Compounding.

• Advanced utilization of excel for data analysis. Preferred experience using VBA to create macros in Microsoft Office applications

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