Process Control Engineer

About the role

At DuBois Chemicals, we’re committed to bringing passion and customer focus to the business. The Process Control Engineer is a key role on the Manufacturing Engineering Team responsible for optimizing process design, increasing operational safety, programming and maintaining automated control systems, and the implementation of capital projects. Successful candidates will improve industrial processes to increase efficiency, reduce cost, minimize waste, extend sustainability, and maximize profitability while improving the safety and quality of operations. This position reports to the Manufacturing Engineering Manager and interacts primarily with plant leadership and operations, supporting the production network.

Responsibilities

• Process Optimization
  • Identify process inefficiencies and implement improvements to reduce costs, minimize waste, and increase efficiency while improving safety and quality.
  • Plan, design, and execute capital projects, ensuring input from the operations floor for successful continued use of new equipment and processes.
  • Utilize data-driven decision-making to achieve operational excellence and meet production targets.
  • Monitor and analyze process data, identifying trends and proposing solutions for continuous process improvement.
  • Perform process capability studies using statistical analysis to determine standard operating limits.
  • Utilize chemical compatibility to determine appropriate materials of construction for pumps, valves, piping, and additional equipment.
  • Conduct Root Cause Analyses for production interruptions, equipment failures, and process breakdowns.
  • Perform ROI calculations to determine project priority and expected savings.
  • Utilize process simulation models to test and find the most appropriate production strategies.
• Automation and Controls
  • Program, troubleshoot, and maintain automated control systems.
  • Configure and install I/O devices including flow control, level control, temperature control, and pH monitoring.
  • Write and test basic PLC and DCS programs for automated operations systems.
  • Maintain and determine upgrades required to the OT system architecture.
  • Perform root cause analyses on control system and automation failures.
• Standardization
  • Create and maintain standard operating procedures, process documentation for equipment, and visual controls for manufacturing operations.
  • Update and maintain manufacturing layouts in AutoCAD, equipment files, and P&IDs.
• Lean Manufacturing & Continuous Improvement
  • Utilize lean principles and Six Sigma methodology to evaluate processes and outline improvements.
  • Develop value stream maps and designs, identifying non-value-added steps and areas for improvement.
• Collaboration
  • Collaborate with cross-functional teams to ensure smooth integration of new processes, software, technologies, and equipment.
  • Act as a liaison between R&D and operations for scale-up processes for new product deployment and formula revisions.

Qualifications and Skills

• “Go to Gemba” mentality as the framework for problem-solving, improving processes, and implementing new projects.
• Strong written and verbal communication skills, with the ability to communicate from the operations floor to the C-Suite.
• Ability to influence without direct authority and build cross-functional relationships to solve complex problems.
• Deep attention to detail to ensure implemented projects will be successful.
• Proven ability to identify, assess, and solve problems in a manufacturing environment.
• Knowledge of manufacturing software systems including OMS, CMMS, PLC, and DCS systems.
• Familiarity with applicable health and safety regulations in a chemical manufacturing environment.
• Ability to travel up to 20% to provide engineering support to additional manufacturing locations outside of Salt Lake City.
• Controls background with preferred experience with Allen Bradley.

Education

• Bachelor’s degree in engineering (Chemical, Mechanical, Industrial, Manufacturing, Computer Science, or related field), or
• 5 years of related experience in lieu of a degree.

Applicants must be authorized to work in the United States on a full-time basis without the need for current or future visa sponsorship.