Job Overview:This role is aligned to the Coffee Operating UnitLocation: 3109 Plant Water Road, Knoxville, TN 37914
Shift & Schedule:This is a salaried position supporting a flexible schedule based on business needs. The role is expected to support operations across all shifts and is typically scheduled for four 10-hour days.
The
Senior Manufacturing Process Engineer serves as a technical leader responsible for optimizing manufacturing processes, equipment performance, automation, and overall production capability. This role provides advanced engineering expertise across the manufacturing operation and partners closely with Operations, Maintenance, Quality, Supply Chain, and Engineering to identify complex opportunities, solve challenging production issues, and implement sustainable improvements.
The Senior Manufacturing Process Engineer will leverage engineering principles, data analytics, automation expertise, and continuous improvement methodologies to improve safety, quality, productivity, reliability, capacity, and cost performance. This position will serve as a technical resource and subject matter expert for the plant, leading complex improvement initiatives and providing direction and mentorship to other engineers and technical team members.
Position Responsibilities- Lead the analysis of manufacturing processes, production data, automation systems, and equipment performance to identify opportunities to improve safety, quality, efficiency, throughput, capacity, reliability, and cost.
- Serve as a senior technical resource for day-to-day manufacturing operations, providing advanced troubleshooting and engineering support for complex process, equipment, and production issues.
- Lead the development, implementation, and standardization of process improvements that increase productivity, reduce waste and variation, improve reliability, and optimize overall manufacturing performance.
- Lead cross-functional root cause analysis and corrective action efforts for complex or recurring production, process, and equipment issues.
- Provide technical leadership for Lean Manufacturing and Continuous Improvement initiatives, including process optimization, waste reduction, standard work, problem solving, TPM, and operational excellence.
- Analyze key manufacturing performance indicators and develop data-driven strategies to address trends, risks, capacity constraints, and performance gaps.
- Establish and maintain process standards, specifications, standard operating procedures, work instructions, and other technical documentation.
- Lead or provide technical direction for production trials, process changes, new equipment installations, technology implementations, and new product introductions.
- Evaluate proposed process and equipment changes and determine impacts to safety, quality, capacity, reliability, productivity, and operating cost.
- Partner with Maintenance and Engineering teams to improve equipment reliability, automation performance, preventive maintenance strategies, and overall asset effectiveness.
- Provide technical leadership in the investigation of process-related quality issues and development of sustainable corrective and preventive actions.
- Lead or support capital projects by defining process requirements, developing technical specifications, evaluating equipment and technology solutions, and supporting installation, commissioning, validation, and startup.
- Develop, implement, and maintain process metrics, dashboards, and reporting systems to measure performance and quantify improvement results.
- Lead the identification and implementation of automation, controls, data, and technology solutions that improve manufacturing capability and operational efficiency.
- Provide technical guidance, coaching, and mentorship to engineers, technicians, maintenance personnel, and operations leaders.
- Train and support production employees and supervisors on new processes, equipment, procedures, and process improvements.
- Partner with OEMs, system integrators, contractors, and external technical resources to resolve complex issues and implement new technologies.
- Ensure manufacturing processes and automation systems comply with company safety requirements, quality standards, regulatory requirements, and applicable policies.
- Lead and participate in cross-functional improvement teams, providing technical expertise and influencing decisions that support plant and business objectives.
- Identify emerging technologies and best practices and evaluate their potential application within the manufacturing operation.
- Establish sustainable processes and controls to ensure improvements are maintained over time.
- Promote a culture of data-driven problem solving, technical excellence, accountability, and continuous improvement across the manufacturing organization.
Total Rewards:- Targeted annual compensation range of $90,000-$125,000.
- This is a salaried, exempt position paid biweekly. Compensation is competitive and commensurate with experience.
Benefits (Effective Day One, Where Applicable):
- Medical, Dental, and Vision Insurance
- Disability Coverage
- Paid Time Off (including vacation and sick leave)
- 401(k) with company match
- Tuition Reimbursement
- Mileage Reimbursement
Benefits are subject to eligibility requirements and applicable collective bargaining agreements.
Requirements:Education- Bachelor's degree in Electrical Engineering, Automation Engineering, Mechatronics, Industrial Engineering, or a related technical field required.
- Advanced degree in Engineering, Automation, Manufacturing, or a related field is a plus.
- Equivalent combination of education and significant relevant experience may be considered.
Experience- 7+ years of progressive experience supporting industrial automation, controls, manufacturing engineering, or related technical functions within a manufacturing, distribution, or highly automated material handling environment.
- Demonstrated experience serving as a technical leader or subject matter expert for complex automation and manufacturing systems.
- Advanced experience with Allen-Bradley PLC platforms, including ControlLogix and/or CompactLogix.
- Advanced experience with FactoryTalk, HMIs, VFDs, servo systems, industrial networking, and automated manufacturing equipment.
- Strong experience troubleshooting electrical controls, instrumentation, robotics, vision systems, and complex automated equipment.
- Demonstrated experience leading automation projects, system upgrades, equipment installations, commissioning, and startup activities.
- Experience leading root cause analysis and implementing sustainable corrective actions for complex manufacturing and equipment issues.
- Strong understanding of preventive and predictive maintenance, root cause analysis, Lean Manufacturing, TPM, and continuous improvement methodologies.
- Demonstrated experience leading cross-functional projects and influencing Operations, Maintenance, Quality, Engineering, and other functional teams.
- Experience working directly with OEMs, system integrators, contractors, and external technical partners.
- Demonstrated ability to mentor and develop engineers, technicians, and other technical team members.
Preferred Qualifications- Experience in high-speed manufacturing, food and beverage, consumer packaged goods, or highly automated distribution environments.
- Experience with SCADA systems, industrial Ethernet networks, SQL databases, data historians, or manufacturing data systems.
- Knowledge of warehouse automation systems, conveyors, sortation systems, robotics, AGVs/AMRs, ASRS equipment, or automated material handling systems.
- Experience with manufacturing execution systems (MES), machine vision, advanced motion control, or Industry 4.0 technologies.
- Six Sigma Black Belt, Lean Six Sigma, or other continuous improvement certification.
- Project management experience, including management of capital projects and external engineering resources.
- Experience developing business cases and capital justifications for automation and manufacturing technology investments.
- Demonstrated success delivering measurable improvements in safety, quality, productivity, capacity, reliability, or cost.
