Process Engineer

About the Role

NuSil (a part of Avantor) is seeking a Process Engineer III to be responsible for all phases of silicone products manufacturing process improvement projects, ensuring successful conclusion within designated time and deliverables. This role implements process improvements to meet quality standards, performs feasibility studies, solves problems, and creates necessary documentation in Agile and SAP environments. The position is full-time and in-person, based in Carpinteria, CA.

Responsibilities

• Provides technical process ownership to core manufacturing processes, improving and developing process methods, systems, and support infrastructure to optimize production rates, efficiencies, yields, costs, and quality performance.
• Supports manufacturing department and SAP operations by creating master recipes, issuing quality notifications, and processing non-conformances.
• Analyzes manufacturing, product, and process data to improve products and monitor processes.
• Participates in KAIZEN events, conducts Gemba walks, 5S’s, R3’s, or PSSR’s.
• Ensures planned engineering progress with respect to process engineering deliverables, planning, scheduling, and preparation of progress reports while utilizing resources effectively.
• Provides operational leadership by managing design calculations, process optimization, sizing and selection of equipment, and review of specifications, datasheets, installation, start-up, and validation of new or improved process equipment and technologies.
• Interacts with customers, internal team members, and vendors to develop process and equipment specifications.
• Prepares qualification reports, flow diagrams, and charts on research data and information.
• Implements and maintains appropriate engineering records consistent with cGMP and ISO regulations for production of Life Science biochemicals and reagents.
• Works closely with engineers, production staff, and quality staff to monitor and improve efficiency, output, and safety of the plant.
• Analyzes downtime to identify chronic/sporadic failures and leads reliability improvement efforts.
• Leads Root Cause Analysis (RCA) and performs PFMEA’s of processes to identify root causes and implement corrective actions.
• Develops and utilizes key reliability metrics to consistently measure performance.
• Supports manufacturing and maintenance efforts as needed by operations.
• Manages multiple projects based on requirements.
• Develops new manufacturing processes and assesses equipment adequacy to meet market/manufacturing demands.
• Identifies new equipment and technologies to support continuous improvement and capacity expansion of core capabilities.
• Designs, validates, and commissions new production equipment and tooling, monitors modifications and upgrades, and troubleshoots existing processes.
• Develops project budgets associated with the procurement of new equipment and technologies.
• Performs other duties as assigned.

Requirements

• Bachelor’s degree in Chemistry, Chemical Engineering, or related field.
• Minimum of 7-10 years of working experience in a manufacturing environment, in an engineering capacity involving chemical manufacturing, scale-up, site transfer, process design, and NPI process for manufacturability; hands-on involvement required.
• Experience in Agile and waterfall project management, pilot and production transfers, and their requirements.
• Proficiency using SAP Hana ERP module.
• Fluency in manufacturing operations, project management, and Kaizen experience.
• Knowledge of basic problem-solving tools (DMAIC), Six Sigma, and lean manufacturing concepts, 5S.
• Familiarity with NuSil processes and products is strongly desired.

Qualifications

• Knowledge of process production activities in a chemical manufacturing environment.
• Applied engineering experience in a GMP manufacturing environment preferred.
• Advanced Excel skills, ability to write macros, and generate pivot tables and graphs preferred.
• Must possess excellent communication and problem-solving skills, be detail-oriented, and flexible to work on multiple projects simultaneously.
• Proficiency in Microsoft Suite, Visual Basic, CAD, and/or SolidWorks preferred.
• Knowledge of OSHA, NFPA, HazWoper, and other governmental regulatory requirements (e.g., 21 CFR Part 820, cGMP, ISO, FDA) preferred.

Pay

The expected pre-tax pay for this position is $86,000.00 - $138,000.00. Actual pay may differ depending on relevant factors such as prior experience and geographic location.