Position OverviewThe Senior Process & Production Engineer provides advanced technical support to plant operations at the Sheboygan site. This role is responsible for independently driving process reliability, performance improvement, and operational stability initiatives across production units.
The position partners closely with Operations, Maintenance, Engineering, Process Control, and site leadership to ensure safe, compliant, and optimized plant performance. This role proactively identifies improvement opportunities, resolves complex process issues, and delivers sustainable improvements to safety, quality, throughput, and cost.
Key Responsibilities1. Operational Process Support & Advanced Troubleshooting- Serve as a primary technical resource for Operations and Maintenance.
- Troubleshoot complex process deviations and reliability issues with minimal supervision.
- Conduct root cause investigations for production losses and process upsets and implement corrective actions.
- Monitor key process variables and proactively address abnormal trends.
- Analyze downtime, yield, and capacity data to identify improvement opportunities.
- Develop and maintain performance dashboards, KPIs, and trend analysis tools.
- Communicate findings and recommendations to site leadership.
- Apply structured problem-solving methodologies (RCA, 5-Why, FMEA, etc.).
2. Production & Process Optimization- Own performance monitoring of yield, raw material efficiency, waste generation, and production rates.
- Identify and implement initiatives to improve safety, throughput, reliability, and cost efficiency.
- Support energy optimization efforts (steam, gas, electricity, nitrogen, water).
- Perform monthly production reconciliation and performance analysis.
- Identify risks to production continuity and recommend mitigation strategies.
- Support waste reduction and sustainability initiatives.
- Scope and justify small capital improvement projects.
3. Automation & Process Control Support- Partner with Process Control to enhance control strategies and improve process stability.
- Maintain operating limits and process documentation.
- Identify and recommend HMI/DCS improvements.
- Ensure historian (VantagePoint) data accuracy and tag integrity.
- Support alarm rationalization and instrumentation troubleshooting efforts.
4. MOC & Project Support- Execute Management of Change (MOC) activities for process modifications.
- Support commissioning, startup, and operator training activities.
- Participate in equipment checkouts and Pre-Startup Safety Reviews (PSSR).
- Maintain and update SOPs, P&IDs, SAP records, and technical documentation.
5. Process Safety & Compliance- Maintain process documentation and operating discipline standards.
- Track and support closure of PHA action items.
- Participate in safety audits and regulatory compliance activities.
- Monitor environmental performance of process systems and identify improvement opportunities
6. Production Planning Support- Provide technical input to production scheduling discussions.
- Review proposed schedule or campaign changes and identify technical risks.
- Support risk assessments related to production changes.
- Other duties as assigned.
CompetenciesTechnical & Analytical- Strong knowledge of chemical manufacturing processes.
- Demonstrated experience with DCS systems and process data analysis.
- Strong troubleshooting capability with ability to work independently.
- Ability to interpret complex operational data and translate into actionable recommendations.
Communication & Collaboration- Clear and effective written and verbal communication skills.
- Ability to work cross-functionally with Operations, Maintenance, and Engineering teams.
- Able to influence without formal authority.
Ownership & Execution- Self-directed and accountable for assigned areas of responsibility.
- Effectively prioritizes work in a manufacturing environment.
- Demonstrates initiative and sound technical judgment.
QualificationsEducation & Experience- BS in Engineering (Chemical preferred) or related technical discipline.
- 5+ years of relevant manufacturing or chemical industry experience.
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