NATURE OF WORK : This is skilled and responsible work, applying engineering theories and principles to problems occurring because of the plant layout or within manufacturing production.
Incumbents in this classification studies and records the time, motion, method, and speed involved in performance of production, maintenance, and other worker operations for such purposes as establishing standard production rates or improving efficiency.
EXAMPLES OF WORK PERFORMED (The following duties are typical for this classification. However, any one position may not include all of the duties listed, nor do the examples cover all of the duties which may be performed.)
Performs process designs by developing preliminary process flow diagrams and provides performance estimates for client requested studies and / or budgetary proposals.
Performs the conceptual process design to provide a complete unit that meets the customer’s stated needs and product specifications.
Makes computer-based process simulation calculations and / or perform hand calculations for process analysis and continuous improvement.
Selects or participates in the selection of proper materials of construction for major equipment and components.
Develops / Prepares process data sheets for major equipment.
Provides process engineering tasks as required to ensure a project is executed cost effectively and passes the required performance test.
Controls and maintains the process flow diagram throughout the project.
Reviews designated major equipment documents received from the selected vendor prior to purchase as needed.
Participates in plant process audits, run it rates and reviews.
Observes workers operating equipment or performing tasks to determine time involved and fatigue rate, using timing devices.
Prepares charts, graphs, and diagrams to illustrate workflow, routing, floor layouts, material handling, and machine utilization.
Studies time, motion, methods, and speed involved in maintenance, production, and other operations to establish standard production rate and improve efficiency.
Recommends revision to methods of operation, material handling, equipment layout, or other changes to increase production or improve standards.
Records test data, applying statistical quality control procedures.
Observes workers using equipment to verify that equipment is being operated and maintain in order to gauge possible process and ergonomic improvement.
Recommends modifications to existing quality or production standards to achieve optimum quality within limits of equipment capability.
Evaluates data and write reports to validate or indicate deviations from existing standards.
Utilizes computer software programs such as Microsoft Office in order to complete data analysis and problem solving.
Interprets engineering drawings, schematic diagrams, or formulas and confer with management or engineering staff to determine quality and reliability standards.
Reviews project engineering documentation and specification sheets to ensure that products are built according to proper requirements.
Analyzes and initiates adjustments and methods for manufacturing process, equipment, testing, and materials.
Initiates ongoing process / product quality improvements.
Troubleshoots problems and develops root cause and corrective actions.
Plans and conducts manufacturing training sessions on production for dimensions, uniformity, and function on new production equipment, processes, and assembly components.
Initiates and sustains change across process and functional areas as assigned to include improvements to ergonomic and EHS issues properly design & functioning using appropriate Lean and Six sigma tools and methodology.
Contributes to relevant design / development processes and reviews as appropriate.
Generates internal and external documentation for products, presentations, and technical reports
Generates and maintains standards for all operations, reports on efficiency and utilization based on standards.
Supports the plant team in tracking and understanding Key Performance Indicators such as percentage of non value added work.
Responsible for production / process systems improvements and reliability, improving system unit operations through the development, testing, and implementation of new technology and overseeing line production operations.
Leads and conducts process experiments as well as documenting and communicating key process learning's.
Provides technical guidance to the plant in terms of process and or equipment troubleshooting
Provides problem solving when / where needed within the key process areas.
Participates in pilot plant testing with product development team pilot plant team
Provides continued long-term support to the product development team
KNOWLEDGE, SKILLS, and ABILITIES :
Knowledge of process engineering as needed to design, install, and monitor development (ie, modifications and upgrades) and troubleshoot existing processes.
Knowledge of simulations used in process design as needed to applying the principles of mass, momentum and heat transfer to process and equipment design;
Knowledge of preparing reports, flow diagrams and charts;
Knowledge of monitoring and improving the efficiency, output, and safety of a plant;
Knowledge of industrial engineering as needed to ensure the process works at the optimum level, to the right rate and quality of output, in order to meet supply needs.
Knowledge of process efficiency as needed to make observations and take measurements directly, as well as collecting and interpreting data from the other technical and operating staff involved;
Knowledge of Lear environmental aspects and impacts as needed to assume responsibility for environmental monitoring and ongoing performance of processes and process plant.
Knowledge of regulatory compliance as needed to ensure that all aspects of an operation or process meet specified regulations;
Ability to build a rapport with other departments as needed to work collaboratively with those responsible for the quality control of raw material, plant product specifications and production schedules;
and the operating crew.
PHYSICAL ABILITIES :
Physical Ability to walk, stand, and sit for prolonged periods of time.
Physical Ability to frequently stoop, bend, kneel, crouch, crawl, climb, reach, twist, grasp, and make repetitive hand movements.
Physical Ability to lift, carry, push, and / or pull light to moderate amounts of weight.
SPECIAL REQUIREMENTS :
Must be willing to work extended periods of time or varying shift hours.
Must be able to work in inclement weather conditions.
Must possess a valid driver’s license.
MINIMUM QUALIFICATIONS :
Bachelor’s degree in engineering and two (2) years relevant experience, or equivalent. Experience in, industrial or manufacturing engineering preferred.