Senior Process Engineer
DSJ Global is currently partnered with a Consumer-Packaged Goods startup who is looking to add a Senior Process Engineer to their new facility outside of Lexington, KY. As Senior Process Engineer, you'll be responsible for enhancing production processes, troubleshooting operational challenges, and ensuring seamless scale-up of new formulas. The ideal candidate is a hands-on problem solver with deep experience in process engineering, particularly in liquid blending, solids blending, and substrate converting.
Responsibilities:
- Lead Process Design & Optimization: Develop, implement, and continuously refine processes for liquid blending, solids blending, and substrate converting to maximize efficiency and minimize waste.
- Scale Up New Products: Partner with R&D teams to transition new formulas and processes from lab-scale to full-scale production, ensuring smooth commercialization.
- Enhance Plant Operations: Oversee process troubleshooting, conduct root cause analyses, and drive operational improvements to enhance product yield, reduce downtime, and improve overall efficiency.
- Support Manufacturing Site Setup: Assist in establishing new production facilities, including equipment selection, commissioning, and scaling processes for high-volume manufacturing.
- Drive Data-Driven Decisions: Utilize process control tools such as value stream mapping, Pareto charts, and statistical analysis to identify inefficiencies and recommend improvements.
- Ensure Quality & Compliance: Maintain rigorous process documentation, including SOPs and batch records, while ensuring compliance with regulatory and safety standards.
- Train & Mentor Teams: Provide guidance to production staff and junior engineers, fostering a culture of continuous learning and operational excellence.
- Ensure Safety & Environmental Compliance: Uphold industry best practices for workplace safety and environmental sustainability across all plant operations.
Required Qualifications:
- Bachelor's degree in Chemical Engineering, Mechanical Engineering, Industrial Engineering, or a related field.
- Minimum of 5 years of experience in process engineering, specifically in liquid blending, solids blending, and substrate converting.
- Hands-on experience scaling up processes from lab-scale to full-scale production.
- Strong background in manufacturing site setup, equipment commissioning, and process optimization.
- Proven ability to troubleshoot complex process issues and drive efficiency improvements.
- Proficiency in process modeling, data analysis, and statistical tools (e.g., CPK, value stream mapping, Pareto charts, fishbone diagrams).
- Experience with Lean Manufacturing, Six Sigma, or other process improvement methodologies.
Preferred Qualifications:
- Master's degree in a related field.
- Lean Six Sigma certification (Green or Black Belt).
- Experience working with consumer goods manufacturing, home care, or chemical-based production.
- Familiarity with process automation and control systems.
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