CI Process Engineer

About the role

The Continuous Improvement Process Engineer drives measurable cost reduction, capacity improvement, and operational performance across pet food manufacturing operations. Utilizing Lean/Six Sigma methodologies and financial acumen, this role partners directly with plant operations to transform process inefficiencies into realized P&L savings, increased capacity, and improved yields. The position is responsible for developing and executing a pipeline of high-value continuous improvement opportunities, from initial opportunity identification and financial justification through implementation, validation, and sustained results - focusing heavily on extrusion, drying, packaging, and raw material utilization.

Responsibilities

• Analyze manufacturing operations, conversion costs ($/lb, $/ton, labor hr/lb), and plant metrics to identify waste and process bottlenecks.
• Evaluate focus areas including raw material giveaway, extrusion yields, dryer losses, bag/film packaging waste, utility consumption (steam, gas, power), and maintenance downtime.
• Quantify potential savings into clear value buckets: Realized P&L Savings, Cost Avoidance, Capacity Expansion, Yield/Material Savings, and Labor Efficiency.
• Build and maintain a plant-wide Continuous Improvement Idea Library and submission process, establishing recognition (KUDOS) initiatives to foster an engaged continuous improvement culture.
• Benchmark operational metrics across manufacturing lines and facilities to standardize best practices.
• Translate prioritized opportunities into actionable capital expenditure requests (CERs), ROI business cases, timelines, and execution roadmaps.
• Partner directly with plant managers, operators, and maintenance teams to execute improvement projects through influence, structured problem-solving, and root-cause analysis (8 Wastes of Lean).
• Optimize core processing parameters, including extruder yield, dryer settings, coating application rates, and line throughput.
• Conduct post-implementation tracking to verify financial savings on the P&L, ensure regulatory/food safety compliance, and establish sustainable standard work practices.

Requirements

• Education & Experience: Bachelor’s degree in industrial, Manufacturing, Chemical, or Mechanical Engineering (or equivalent experience) with 5–7 years of hands-on manufacturing experience, preferably in pet food, food processing, or high-speed CPG operations.
• Travel: Willingness and ability to travel up to 50% to support East Region plant facilities and assist in ongoing CI team projects.
• Continuous Improvement: Proven expertise in Lean Manufacturing, Six Sigma tools (Green/Black Belt preferred), root-cause analysis, and systematic waste elimination.
• Financial Acumen: Strong capability to connect engineering changes to financial metrics (P&L, capital planning, conversion cost reduction).
• Technical Skills: Advanced Excel and data analysis capabilities; familiarity with extrusion, thermal processing, or bulk material handling is a strong plus.
• Leadership & Communication: Track record of driving cross-functional alignment and leading site-level change without direct authority.
• Physical Demands: