Lead Process Engineer

Roles and responsibilities

A Lead Process Engineer is a senior engineering professional responsible for overseeing the design, optimization, and implementation of processes within a manufacturing, production, or industrial environment. This role is essential in improving the efficiency, productivity, and quality of operations, ensuring that processes are designed to meet both technical and business objectives. The Lead Process Engineer typically leads a team of engineers and works closely with other departments, such as operations, production, quality assurance, and R&D.

Key Responsibilities of a Lead Process Engineer:

1. Process Design and Optimization:

   • Develop Process Flows: Design and optimize manufacturing or operational processes, ensuring they are efficient, scalable, and meet quality standards. This includes the selection of materials, equipment, and technologies.
   • Process Improvements: Continuously assess existing processes to identify areas for improvement, including reducing waste, increasing throughput, and optimizing energy use.
   • Efficiency Analysis: Perform process analysis to assess operational efficiency, including time studies, resource utilization, and bottleneck identification.

2. Project Leadership and Management:

   • Project Oversight: Lead cross-functional teams in the development and implementation of new processes, systems, or production lines. Ensure that projects are completed on time, within budget, and to required specifications.
   • Risk Management: Identify potential risks in process changes or new process implementations and develop mitigation strategies.
   • Process Scaling: Scale up lab or pilot processes to full-scale production, ensuring that scaling does not impact process efficiency or product quality.

3. Quality Control and Assurance:

   • Quality Standards: Ensure that processes are designed and implemented to meet both internal and external quality standards, including regulatory and safety requirements.
   • Root Cause Analysis: Lead investigations into process failures or quality issues, performing root cause analysis (RCA) and implementing corrective actions to resolve them.
   • Continuous Improvement: Advocate for continuous improvement using methodologies like Six Sigma, Lean, or Kaizen to enhance process reliability and performance.

4. Collaboration and Cross-Functional Work:

   • Interdepartmental Collaboration: Work closely with other teams, including operations, production, quality assurance, R&D, and maintenance, to align process designs with operational needs and company goals.
   • Training and Development: Provide guidance and training to junior engineers or operators on process design, process control, and best practices.
   • Technical Support: Provide technical support to the production team and resolve issues related to process performance or equipment functionality.

5. Process Documentation and Reporting:

   • Documentation: Ensure that all process designs, changes, and optimizations are well-documented and compliant with company standards, regulatory requirements, and best practices.
   • Reporting: Prepare and present reports on process performance, cost savings, improvements, and project statuses to senior management and stakeholders.
   • Compliance and Safety: Ensure that processes adhere to health, safety, and environmental regulations, and that risk assessments are conducted as required.

Desired candidate profile

• Process Engineering Knowledge:

  • In-depth understanding of process engineering principles, including thermodynamics, fluid mechanics, materials science, and manufacturing processes.
  • Knowledge of process design tools such as AutoCAD, P&ID (Piping and Instrumentation Diagram), and Process Flow Diagrams (PFDs).

• Problem-Solving and Analytical Skills:

  • Strong ability to diagnose process issues, identify root causes, and develop efficient, cost-effective solutions.
  • Familiarity with statistical tools for process analysis, such as SPC (Statistical Process Control) and DOE (Design of Experiments).

• Project Management:

  • Strong project management skills, including the ability to lead teams, manage budgets, and meet deadlines. Familiarity with project management methodologies like Agile or Waterfall is beneficial.
  • Experience in managing complex projects and coordinating with multiple departments to ensure smooth implementation.

• Lean Manufacturing and Six Sigma:

  • Expertise in Lean and Six Sigma methodologies for process improvement, waste reduction, and quality enhancement. Certifications such as Lean Six Sigma Black Belt or Green Belt are often required.

• Communication and Leadership:

  • Excellent communication skills to effectively convey technical information to non-technical stakeholders and senior management.
  • Strong leadership skills to mentor and guide teams, manage conflicts, and ensure high levels of collaboration across departments.

• Quality Control and Regulatory Compliance:

  • Knowledge of quality assurance and control principles, including standards such as ISO 9001, FDA (if applicable), or other relevant industry standards.
  • Familiarity with health, safety, and environmental regulations relevant to process engineering (e.g., OSHA, EPA).

• Technological Proficiency:

  • Proficiency with engineering software and tools such as Aspen Plus, MATLAB, Simulink, AutoCAD, or SolidWorks for process modeling, simulation, and design.
  • Familiarity with automation and control systems, such as PLC (Programmable Logic Controllers), SCADA, or DCS (Distributed Control Systems).