Process Engineer II, R&D

Company: Simmons Foods
Location: Emporia
Posted on: August 2, 2022

Job Description:

PURPOSE OF THE POSITIONThe Process Engineer II role is responsible for leading the improvement of existing production processes and workflows to improve yields and reduce manufacturing costs, as well as leading the validation of new processes. Works closely with the Product Development and Innovation teams to develop optimal new processes and technologies to bring new products to market. Leads troubleshooting initiatives in the manufacturing plants and makes recommendations for improvements. Collects relevant information, summarizes and presents the information in a manner that can be understood by all levels of the organization. Uses data and subsequent analysis to make recommendations to their supervisor. Assists in facility design and selection of new equipment.ESSENTIAL POSITION RESPONSIBILITIESDevelopment of Processes. Participates and often leads in the evaluation and optimization of existing processes with minimal supervision. Works closely with internal stakeholders and technical staff of equipment suppliers and customers. Leads in the development, scale-up, and commercialization of new processes to minimize cost and maximize simplicity and flexibility in accordance with committed time and budget constraints. Evaluates alternative equipment suppliers and summarizing capabilities and recommend suitable candidates based on key findings. Participates and often leads in the implementation of new process installation and final validation of equipment. Maintains and further develops competencies in food technology and new equipment offerings by attending technical meetings to identify new opportunities with respect to product/process.Validation of Process Improvement. Evaluates existing processes and optimize to maximize product performance such as flow rate, product appearance, particle size, and product consistency as well as plant efficiencies. This may involve manufacturing processes such as grinding, blending, emulsifying, vacuumizing, and filling as well as order/rate of addition and temperature of raw materials and finished products. This may also involve processes during product changeovers with recommendations made back to their operations on optimal production scheduling. Develops and implements testing plans to identify critical quality points (process control points) for various product types. Evaluates various throughput rates and identify production limitation and equipment capability. Harmonizes processing where possible to improve plant efficiency and minimize potential errors. Participates in the development of process flow diagrams to outline current and new processes. Provides cross-functional teams thorough written instructions for the successful implementation of process changes.Validate Equipment. Participates and often leads in the calibration of new equipment with respect to metering rates to optimize processing. Screens alternate suppliers of manufacturing and product evaluation equipment. Summarizes strengths and weaknesses of the various options and makes recommendations. Completes equipment validation studies through the operational qualification (IQ/OQ) and long-term validation (PQ) to qualify new equipment. Participates and often leads in the evaluation of online equipment which allows for early detection of process errors/product non-quality. Conducts pilot plant testing both internally or at supplier facilities to verify new process capability. Utilizes validation to assist FSQA with SPC programs ensuring the process is controllable.Support Operations and Supply Chain. Supports and often leads supply chain initiatives as needed and participates in problem-solving of plant technical issues. Supports supply chain initiatives including formula transfer among plants, evaluation of new suppliers of raw materials, new and alternative packaging, thermal process impact, and evaluation of processing parameters. Leads the development of plant SOP's and troubleshooting guidelines. Utilizes SPC and SCADA platforms for process evaluation and optimization. Identifies, validates, and documents personal cost savings requirements.Participates as a member of the Team. Participates in the ongoing development, communication, and implementation of team concepts, programs, and policies; coordinates work to ensure best practices with all team members. Attends appropriate team meetings. As a member of the Team, fosters strong cohesiveness regarding all major issues; e.g., direction, annual plan, budget, policy changes, etc. Accepts responsibility to quickly identify any areas that lack cohesiveness, bringing them to the attention of the team leader and working with the team in a supportive manner to resolve issues and actively look for ways, and reinforce actions needed, to achieve synergy possible within the larger organization.Simmons Operating systems principles and objectives: Is familiar with Simmons' established operating systems (e.g. quality, security, office environment, company policies, LEAN); understands the responsibility to maintain familiarity with the systems and this position's role in support of these systems - including a consideration of the impact of individual actions on the systems and the responsibility to communicate concerns and improvement ideas.Performs other duties as necessary in support of business objectives: This position description is intended to guide the activities of the person in this position and is not intended to limit the thinking and creativity of the person as to the work of this function nor is it intended that this describe all the work that may be required of the person in this position.Physical Activities: Must be able to work on a computer for an extensive amount of time. Must be able to stand or walk for many hours in any of our production facilities. Communicates with Customers, Vendors, and Employees via telephone, in person, and/or electronic mail.Personal Protective Equipment (PPE): As needed in the required environment.Travel: Travels domestically to and from multiple facilities or work-sites or customer visits, often requiring overnight stays. Approximately 25% travel.Technical Experience: 3+ years of related industry experience required. Must have excellent computer skills with respect to the Microsoft Office Suite. Experience with AutoCAD is a plus. Strong data entry skills are required. Intermediate to advanced level skills in Excel and PowerPoint as well as experience preparing documents for presentation. Experience in commercial manufacturing and process development and in the food industry is desirable. Should have a working knowledge of process mapping. Must have leadership qualities and flexibility with respect to job requirements. Knowledge of specific requirements in the US is essential to successful job performance. Ability to work as part of a team and work effectively with a geographically dispersed group.Industry Experience: 3+ years with a preference for related industry experience.Minimum Education: Bachelor's degree in Chemical, Biological, or Mechanical Engineering.Preferred Education: Master's degree in Chemical, Biological, or Mechanical Engineering. Licensed as a Registered Professional Engineer is a plus.This is a Salary Exempt position.

Keywords: Simmons Foods, Topeka , Process Engineer II, R&D, Engineering , Emporia, Kansas