Process Engineer II, R&D
Company: Simmons Foods
Location: Emporia
Posted on: August 2, 2022
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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
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