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Process and Improvement Engineer Alsip, IL This role serves as a technical resource in the areas of control system and automation, plant reliability, cost management, product quality and HES performance & compliance to assist work teams to optimize the daily operations of a batch emulsion polymerization plant. This position will also interface with corporate Manufacturing & Busines Unit resources, though there is no direct reporting structure.
Key responsibilities
25%
- 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 meet goals and commitments safely and within budget.
- Financial / OPEX - This position is responsible for identifying, personally driving, or serving as champion for continuous improvement projects that will accelerate growth in market share, improve cost and/or waste reduction. The incumbent will work closely with the Improvement Leader who is responsible for maintenance & capital projects to clearly determine project ownership as appropriate.
25%
- 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 and maintains 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 recipe 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.
- Engages the Recipe Industrialization 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.
- Generate ideas that can be implemented with Recipe Industrialization group support on recipe related cycle time and quality improvements. Coordinate these improvement activities with Operation Excellence work process to insure time/cost savings are appropriately captured.
15%
- Serve as the site control system focal person.
- Lead the site process automation team.
- Works with BU process automation team for resolving issues to control system hardware and code.
- Perform on site system maintenance to the system as needed.
- Manage relationship with local service provider.
- Act as site focal point for Cybersecurity team.
15%
- Lead site Overall Equipment Effectiveness
- Track and report OEE.
- Analyze OEE data and develop improvements.
- Use Management of Change (MOC) process to document and control process changes.
15%
- Provide leadership as needed to improve HES performance - consider HES impact on all aspects of continuous improvement.
- Support internal and external environmental reporting through data retrieval and analysis.
- Communicate technical information and issues to plant personnel and technology centers.
- Initiate changes to Plant Operating procedures and work with Production Technicians to ensure procedures are valid and up-to-date.
- Lead or participate in Process Hazard Analyses, Management of Change, Pre-Startup Safety Reviews, and Incident Root Cause 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.
5%
- Co-Coordinator for Arkema Operator Engagement & Problem-Solving Initiative (SMART)
- Co-coordinator for overall AIMS program to ensure completion of required activities through individual owners of the quality, safety, environmental, etc. components of the system. Support preparations for internal & external audits
- Participate in site safety inspections
- Completes all assigned Impact items
- All other duties as assigned
Required Education/Qualifications /Work experience
- Bachelor's degree in Chemical Engineering required.
- 3 to 5 years of experience in Chemical manufacturing.
- Preferred experience in: Maintaining, updating and programming Delta-V process control system; Emulsion Polymerization on a production scale (safety hazards, technical methods, etc.); New product scale up (from lab scale to commercial scale); Handling of acrylic monomers and understanding of chemistry involved with handling acrylic monomers in emergency response situations; Process Safety (Layers or Protection Analysis - LOPA); and 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.
Context and environment
- 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, R&D, process automation, and management teams.
- Ability to respond to calls and serve the site on-call duty rotation to support 24/7 plant operation.
- Supports all AIMS initiatives.
- Comply with Regulations, Legal and Internal Requirements as made known by the site and 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.
- Identify and communicate potential gains or possible improvements to the management system.
- 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.
Company benefit plan details are available at benefits.arkema.com
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Arkema Inc
Jan 16, 2025