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Job Summary (include Context and Environment)
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The Production – Process Control Engineer role acts as the technical resource for operations personnel, applying technical skills to optimize plant operations, resolve plant problems and enable production of low cost, quality products. This position will also serve as a resource for maintaining process control and instrumentation tools for the site. This position may at times serve as a backup for the Operations Manager.
This is a 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.
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Essential Duties & Responsibilities with % Breakdown:
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50% Production Engineering:
- Understands all applicable process technology, equipment, unit operations, and control technology. Works with Technical Advising, Process Research, and plant personnel to optimize operations and meet business and plant goals for HES, production, cost, and quality.
- Participate in advanced troubleshooting, conduct appropriate root-cause analysis, and ensure corrective actions are implemented to address unplanned events as defined in department trigger criteria.
- Supports daily activities and production requirements, helping ensure goals and commitments are met safely and within budget.
- Monitor, report, and provide input to daily production, shipping activities, product quality, and direct adjustments to production and shipping plans as appropriate. Ensure continuous evaluation and implementation of improvements.
- Serves as the Scale-Up Coordinator for the facility - assist with plant recipe system and coordinate new product development activities assigned to the plant.
- Have a working knowledge of the process safety management standard, assist in resolving issues identified in internal and external audits, perform gap analysis against current performance, and lead action plan implementation.
- Lead or participate in Process Hazard Analyses, Management of Change, Pre Startup Safety Reviews, and Incident Investigations.
- 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.
- Understands and applies skills and knowledge in Statistical Process Control (SPC) technology to maximize plant asset utilization and produce low cost, quality products.
- Participate in project commissioning and startup activities.
- Deliver value to the business through the effective use of Lean Six Sigma methodologies, asset utilization tracking and analysis through RtPM, and project management work processes.
35% Process Control Engineering:
- Assist the plant/BU automation engineer in developing and maintaining operator interface graphics, creating and/or making minor modifications to existing control system programming codes, and maintaining control system hardware
- Lead, or assist the plant/BU automation engineer, in providing training and support for the use of the tools for the plant such as the DeltaV control system, Bar coding, Excel tools, web pages, databases, asset utilization tracking program (RtPM), and other technology center business tools.
- Serve as technical project resource to optimize the DCS in St. Charles. Leverage knowledge of existing plant operations to support DCS improvements.
- Maintain detailed functional specifications for programming in the DCS.
- Participate in project commissioning and start up activities, including tuning of control loops, validations of alarms and interlocks, as well as overall control code functionality per the specification.
- Provide support to manufacturing plant staff in training on process control code and functionality.
10% HESQ:
- 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 third-party Industrial Complex, St. Charles Operations facility, as well as the rules set by the business unit (BU) and Arkema, Inc.
- Comply with all standard operating procedures and work instructions to ensure productivity, quality assurance and cost effectiveness.
- Review work areas for potential losses and report hazards to supervision.
- Report near misses to supervision.
- Report incidents or accidents to supervision.
- Participate in HES activities provided by site management and Arkema, Inc. (e.g., Behavioral Based Safety, SWAT, etc.)
- Support and promote the reporting of all health, safety, environmental, near-miss, accident or injury incidents.
5% Development:
- Develop skills required to support the St. Charles plant through professional development of technical skills, interpersonal relationship skills, management skills, and community relations. Ensure that specific goals are developed that correspond with Plant objectives and initiatives.
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Minimum Qualifications and Education Required
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Min Years of Experience
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Minimum of 2 years of experience in a manufacturing environment required (chemical batch processing experience preferred).
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Education and area of focus
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Bachelor’s degree in Chemical Engineering required.
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Certifications/Trainings:
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-Six Sigma experience preferred
-Process Safety experience preferred (PHA, LOPA, Safety Instrumented Systems)
-Root Cause Investigation experience preferred (e.g., Cause Map, TapRoot, 5-Why)
-Familiarity using IP-21 or similar data historian preferred
-Hands on knowledge and experience with ISO, Integrated Management Systems, SPC & SQC.
-DCS and batch manager experience preferred
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Competencies -Knowledge Skills & Abilities (KSAs)
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-Strong problem solving skills and ability to implement process improvement from concept through project completion (project management skills).
-Demonstrated leadership skills as well as demonstrated ability to develop goals and actions to improve performance.
-Strong Proficiency in Microsoft Office Suite (Word, Excel, PowerPoint) is required
-Strong communication skills (both written and verbal)
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HES Requirement – All Jobs
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-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
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Physical Demands/Working Conditions
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This position works at a chemical manufacturing site. Must be able to climb ladders and lift up to 50 lbs.
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