Share this Job

Lead Recipe Industrialization Engineer Job


Location: 

Cary, NC, United States

Employment Type:  Regular
Category:  Engineering & Technology
Posting Date:  Sep 14, 2022

Division:  Coating Resins             

Location: Cary, NC

 

 

SITUATION IN ORGANIZATION

The position reports to the Americas Centralized Coating Resins Recipe Industrialization leader. The Recipe Industrialization group is aligned to the Global manufacturing excellence center.

 

JOB DIMENSIONS

This is a centralized role within the global manufacturing excellence center supporting Coating Resins. The expectation is to lead the Recipe Industrialization efforts at the manufacturing facilities. This includes directing business prioritized scale-ups for product recipe and technology transfers, supports advanced process and engineering troubleshooting, product recipe capability reviews to support stage gate product commercialization process, raw material alternative qualifications, drive productivity improvements, provide technical input on product compatibility and quality. This role also coordinates quality technical activities to ensure investigation and resolution of customer quality needs.

 

This role will lead the above activities for at least two to three manufacturing facilities within the Coating Resins business. It will cover a total of at least 20+ core products.

 

In addition, this role directly interfaces with key Arkema customers by working to bring on new toll product volume. This role leads new toll product initiatives for the Coating Resins business, which has delivered between two to five toll products estimated between 10-30MM lbs+ over the past five years.  This type of support is provided to several global key accounts for Arkema, including Sherwin Williams, PPG, and UPM Raflatac, to name a few.

 

A key aspect of this role includes training and mentoring new plant production and process engineers in the key manufacturing facilities that the role is responsible for. This support training is on product chemistry, recipe, scale-up and product change management processes. The role will also provide after hours and weekend technical on call support for the manufacturing facilities if product related safety or quality issues occur.

 

Lastly, this role will provide support for Coating Resins product and process troubleshooting globally, by leading global product migrations into and out of the Americas region.

 

This role is based at the Cary, NC site. Key activities and responsibilities include work requiring coordination of experiments by R&D lab technicians at times, visual assessment of product experimentation and testing results, and management of product samples from R&D and manufacturing facilities required to support scale ups and other projects. This will require an on-site presence in the office and labs targeted about 60% of the time.

 

KEY ACTIVITIES AND RESPONSIBILITIES

Process Development, Scale up, and Improvement (50-60%):

  • Works with R&D Applications and Process development teams to ensure alignment and delivery of technical goals, strategies and coordination of appropriate resources across the cross-functional team. Supports the manufacturing capability assessment of new products and implementation of these new products across the manufacturing grid.
  • Utilizes the stage gate product development work process to bring new products to commercialization. Leads through the preparation activities to scale up products at the plant, which includes managing experimentation in the lab, advanced analysis of capability and fit within the manufacturing facilities, assessment of product robustness, and alignment of quality specification limits. 
  • Implements new and modified products within the manufacturing facilities. This includes leading the development of the product recipe procedures and specific process steps, calculation of product specific safety setpoints, understanding and modification of plant batch control system recipe procedures. This role leads these efforts with support and review from the plant based recipe coordinator. 
  • Works closely with Plant-based Recipe Industrialization Coordinator role to drive improvements to existing and new recipes/processes with respect to safety, quality, and productivity and improved processing of products. Resolves technical quality issues affecting production utilizing advanced quality and process statistical analysis. Utilizes continuous improvement methodologies (including Six Sigma) when appropriate.
  • Documents technical findings through either experimental work, production trials on pilot or plant scale, or manufacturing data analysis. Communicates learnings to improving product consistency and quality. Works with Plant based Recipe Industrialization to evaluate and provide the key performance indicators for the success of scale ups.
  • Recipe management through maintaining master product recipe and composition documentation. This includes submission and working closely with the Product Regulatory group to provide the data needed for creation of product Safety Data Sheets (SDS). Reviewing any change to the recipe with the appropriate approvals through EMOC and or documented revisions.
  • Leads projects with direct customer interaction, which include quality improvement initiatives of Coating Resins products at the customer or supporting production of a customer owned toll product at Coating Resins manufacturing facilities. In the case of customer owned toll product, this role becomes the primary support focal point for the product to the customer.
  • Liaises with global teams to understand regional customer needs and provide solutions.
  • Translates business goals to identify potential projects including those for manufacturing facilities. Develops and refines project ideas, obtains business alignment and leads projects to completion.

 

 

Raw Material and Quality Support (10-20%):

  • Support identifying and qualifying suitable raw material substitutions for existing recipes.  This delivers significant reduction in risk due to single sourced raw materials, as well as potential cost savings for lower cost alternatives.
  • Design and execute synthesis projects to address process deficiencies noted in current products.  This includes development of design of experiments (DOE), analysis of results using statistical methods, interpretation and coordination of advanced analytical test method results to support these projects.  In addition, this role must then work closely with R&D and the commercial account teams to understand and align with any customer specific applications testing requirements.
  • Work closely with other business personnel to transfer current products to new locations including tollers. This includes travel to assist scale-ups and applications testing to confirm performance targets are met.

 

Project Management (20%):

  • Translates business goals to identify potential projects including those for manufacturing facilities. Develops and refines project ideas, obtains business alignment and leads projects to completion.
  • Leads monthly scale up prioritization to ensure alignment across all functions and clear timelines for completion of activities.  This involves leading this effort including approximately 12-15 people across business management, manufacturing, supply chain, quality, and R&D.
  • Development of project plans, technical approaches, timelines, deliverables for assigned projects.
  • Directs project teams of five to seven people in various functions in the execution of project plans.
  • Prepares timely project updates, presentations, and report to peers and business stakeholders.  Ensures completion of formal reports upon completion of projects.
  • Supports stage-gate process through project management, tracking and reporting practices.
  • Translates business goals to identify potential projects. Develops and refines project ideas and submits them to management for consideration.
  • Leads product stage gate projects with customers for new toll projects.
  • Leads projects with new potential toll manufacturers to produce Arkema products, this includes ensuring alignment with supply chain, quality, safety, and business functions to meet project objectives.
  • Leads global efforts to ensure product consistency in Coating Resins projects across all regions.

 

CONTEXT AND ENVIRONMENT

  • Global interaction with plants, process and project engineers, R&D managers, business managers for supporting division's manufacturing and process technology goals.
  • Coordination with R&D and pilot plant activities.
  • Participate in cross- functional teams to ensure the success of projects.
  • Works closely with the plant based recipe industrialization Coordinator role to drive business-prioritized technology activities associated with new and existing products.
  • Works closely with applications and product development chemists in the development of new products.
  • Works with manufacturing to ensure optimization of manufacturing efficiency of products.
  • Works with quality to improve production capability of recipes and resolving raw material supply issues.
  • Works with global team to leverage product learnings and efficiencies across the business.
  • Supports the site HES policy and complies with all regulatory and internal requirements.
  • Participates in HES activities provided by site management and Arkema Inc. (e.g., Behavioral Base Safety, SafeStart, etc.).
  • Supports and promotes the reporting of all health, safety, environmental, near-miss, accident or injury incidents.
  • As needed travel (up to 40%) to the plants and contractors to obtain data, assist in design and assist in start-ups.

 

QUALIFICATIONS / EXPERIENCE REQUIRED

  • A degree in chemical or mechanical engineering is required. Demonstrated knowledge of advanced theory and principles is required.
  • Eight or more years of progressive engineering experience in chemicals. 
  • Key skills include:
    • Experience in batch or semi-batch processes;
    • Advanced skills in analyzing processes such as reactor design, reaction kinetics, agitation/mixing, heat transfer, separations, drying, powder processing and handling, etc.
    • Advanced skills in modeling chemical processes, such as statistics, process simulation, thermodynamics, etc.
    • Knowledge of emulsion polymerization fundamentals.
  • Demonstrated experience problem solving using relevant synthesis, application and analytical techniques.
  • Substantial track record in innovation and engineering problem solving independently and/or collectively.
  • Skilled in handling multiple tasks, organizing and planning.
  • Skills in oral and written communications.
  • Networks in the technical community, inside and outside of Arkema.

 

DEMONSTRATED COMPETENCIES

  • Demonstrated leadership in improving HES compliance and performance.
  • Self-motivated individual with ability to identify and recommend technical opportunities for value and growth and to arrive at solutions independently.
  • Demonstrates strong ownership for areas of responsibility.
  • Anticipates problems and builds in solutions.
  • Ability to work in team environment.
  • Strong communication skills; possesses ability to interpret and explain complex technical issues to a variety of audiences.
  • Consistently meets deadlines, and holds others accountable for doing so as well.

Building on its unique set of expertise in materials science, Arkema offers a portfolio of first-class technologies to address ever-growing demand for new and sustainable materials. With the ambition to become in 2024 a pure player in Specialty Materials, the Group is structured into three complementary, resilient and highly innovative segments dedicated to Specialty Materials - Adhesive Solutions, Advanced Materials, and Coating Solutions - accounting for some 80% of Group sales, and a well-positioned and competitive Intermediates segment. Arkema offers cutting-edge technological solutions to meet the challenges of, among other things, new energies, access to water, recycling, urbanization and mobility, and fosters a permanent dialogue with all its stakeholders. The Group reported sales of €9.5 billion ($10.6 billion) in 2021, and operates in 55 countries with 20,500 employees worldwide.

The diversity of its employees is an asset that the Arkema group wants to preserve. Its non-discrimination policy applies to recruitment, salary levels and career management. The Arkema group is committed to ensuring diversity among its employees.

Arkema Inc. provides equal employment opportunities (EEO) to all employees and applicants for employment without regard to race, color, religion, sex, national origin, age, disability or genetics. In addition to federal law requirements, Arkema Inc. complies with applicable state and local laws governing nondiscrimination in employment in every location in which the company has facilities. This policy applies to all terms and conditions of employment, including recruiting, hiring, placement, promotion, termination, layoff, recall, transfer, leaves of absence.


Job Segment: Thermal Engineering, Supply Chain, Chemical Research, Manufacturing Engineer, Compliance, Engineering, Operations, Legal