Production Engineer Job

Location: Alsip

Job Title: Production Engineer

Pay Range : $79,800 - 105,700

Situation in organization

(List the title to Whom this Job Reports, direct and Indirect reports (by Title), matrix relationships, etc.)

Position reports directly to the Alsip Maintenance & Technology Manager.

Job dimensions

(Position summary and scope of role: volume, Number of sites, etc.) ** May include Confidential information (not to be shared on job postings) **

This role serves as a technical resource in the areas of product quality, plant reliability, cost management, and HES performance & compliance to assist work teams in daily operations to optimize plant operations of a batch emulsion polymerization plant.

Key Activities and responsibilities

(include % of time (using ranges) for each item next to each activity, totaling to 100%; use increments of 10% and higher; Balance of smaller items can fall into “other Duties as assigned”)

20-30%

• Understand all applicable process technology, equipment and control technology.
• Work with local and business unit teams to optimize operations and meet business / plant goals (i.e. Health Environmental and Safety (HES), quality, cost, production, etc.).
• Supports daily activities and production requirements, helping ensure goals and commitments are met safely and within budget.
• Lead site Overall Equipment Effectiveness (OEE)
• Track and report OEE
• Analyze OEE data and develop improvements

30-40%

• Serve as the Recipe Industrialization Team (RIT) Plant Coordinator. 
• Serves as the Scale-Up Coordinator for the manufacturing facility. Participates in the scale up prioritization meetings to drive business level scale up activities at the plant to completion.
• Owns the plant recipe system and serves as the coordinator for new product development activities assigned to the plant.
• Communicates results using the scale up communication form summarizing all RIT related activities. This includes any significant recipe change, product scale up, alternate raw material trial, or cycle time improvements.
• Provides in plant technical support to monitor scale up and/or troubleshooting activities.  This may involve non-traditional work scheduling.
• Initiates changes to plant Batch Operating Procedures (BOP’s), new raw materials (both alternate supplier and new chemicals to the plant), and plant distributed control system (DCS) recipes. Ensure the changes are documented in a revision history and that the management of change (MOC) process is effectively executed.
• Leads and drives advanced troubleshooting, conducts appropriate root-cause analysis, and ensures corrective actions are implemented to address unplanned quality and process events as defined in department trigger criteria.  Distribute timely communication of results to business/functional stakeholders.
• Engages the RIT and/or Technology Team for technical support as necessary to participate in troubleshooting and/or investigation activities.
• Monitors, reports, and provides input to daily production schedule concerning recipe compatibility and the potential impact of product quality. Identifies adjustments to production and shipping planning as appropriate. Ensure continuous evaluation and implementation of improvements.
• Participate and provide feedback in manufacturing capability analysis for new product ASAP Gate process. Provide feedback to support Gate 4 commercialization.
• Generate ideas that can be implemented with RIT support on recipe related cycle time and quality improvements.  Coordinate these improvement activities with Operation Excellence work process to ensure time/cost savings are appropriately captured.

20-30%

• Provide leadership as needed to improve HES performance.
• Communicate technical information and issues to plant personnel and technology centers
• Initiate changes to Plant Operating procedures and work with Production Technicians to ensure changes are valid and up to date
• Maintain and support Delta-V control system
• Lead or participate in Process Hazard Analyses, Management of Change, Pre Startup Safety Reviews, and Incident Investigations.
• Participate in project commissioning and startup activities, including tuning of control loops 
• Deliver value to the businesses through effective use of Six Sigma methodologies, asset utilization and project work processes 

10-20%

• Completes all assigned Atlas MOC and incident action items
• All other duties as assigned.

Context and environment

(include % travel, if applicable; Three HES References Below are required on all descriptions; site may have additional HES references; for physical demands refer to the job Demand Form for this role)

• This position will be based in Alsip, Illinois.
• High profile / key position within the plant which works closely with every department.
• Has direct daily involvement with most of the activities in the facility.
• Maintain high level of communication with operations, process research, process automation, and management teams.
• Supports all AIMS initiatives
• Commitment to HSEQ
• Comply with the HSEQ Policy.
• Comply with Regulations, Legal and Internal Requirements as made known by the site and by the business unit (BU).
• Comply with the rules of the specific location to which one is assigned as well as the rules set by the business unit (BU) and Arkema Inc.
• Comply with all standard procedures and work instructions, aka SP, SOP, PWI, TM, to ensure productivity, quality assurance and cost effectiveness.
• Review their work areas for potential losses and Report hazards to the direct supervisor.
• Report Near Misses to the direct supervisor.
• Report Incidents or Accidents to the direct supervisor.
• Identify and communicate potential gains or possible improvements to the management system.

• Participate in HSEQ activities provided by the site management, Arkema Coating Resins and Arkema, Inc.
• Ensures workplace safety by conducting safety observations and reviews while adhering to safety regulations and procedures.

Required Education/Qualifications /Work experience

(Include Degree attained and specialty of Education, Certifications/Licenses, Years and Type of Relevant Experience, Systems proficiency, etc.)

• Bachelor’s degree in Chemical Engineering required
• Minimum of 2 years of experience in:
1. Chemical manufacturing
• Preferred experience in:
1. Maintaining, updating and programming Delta-V process control system
2. Emulsion Polymerization on a production scale (safety hazards, technical methods, etc.)
3. New product scale up (from lab scale to commercial scale)
4. Handling of acrylic monomers and understanding of chemistry involved with handling acrylic monomers in emergency response situations
5. Process Safety (Layers or Protection Analysis - LOPA)
6. Root Cause Investigation strategy
• Familiarity using IP-21 or similar
• Six Sigma experience preferred
• Solid knowledge/experience with HES Performance & Compliance, Cost Management, Plant Reliability, Product Quality and Personal Development.

Demonstrated Competencies (Describe behaviors necessary for role)

• Strategic thinker with strong analytical skills
• Strong communication skills (both written and verbal)
• Demonstrated leadership skills; as well as demonstrated ability to develop goals and action to improve performance.