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Production - Process Improvement Engineer


  • Applies engineering principles to design, modify, or develop facilities, testing, machines, equipment or processes used in processing Sulfuric Acid in a regeneration sulfuric acid unit.

  • Maintain daily Overall Equipment Efficiency (OEE) performance data for the operating unit via spreadsheet.

  • Analyzes existing acid process, equipment, and performance to determine optimal plant operations.

  • Utilize OSI PI software to diagnose plant problems and enhance unit performance improvements.

  • Maintain up-to-date SUMO data for the Unit. (SUMO = Performance data that determines overall plant "well being" with respect to plant rate and efficiency of process equipment.

  • Utilize technical information concerning manufacturing or processing techniques, materials, properties, and process advantages and limitations to improve long-range improvements in the plant.

  • Completes small capital project scope development and execution of small projects (BCER < $25k)

  • Develops and implements project activities through the coordination of efforts of subcontractors, maintenance, production departments, and other operational personnel. Perform Scope activities which include, design, design review, establishes timeline, material procurement, resource allocation, project execution, coordinate effort between all involved parties, monitor/track progress to ensure adherence to schedule. Attend status meetings to ensure safety, and quality compliance.

  • Develop plant skills and knowledge of the Regen sulfuric acid process in order to actively participate and direct meetings to drive Unit goals - Leadership team meetings, SUMO Audits, and other engineering discussions.

  • Tracks procedure and process changes utilizing Management of Change form (MOC) to document the coordination and communication to appropriate personnel as to the stages of implementation till completion.

  • Utilize interpersonal skills to effectively communicate with and actively involve Unit 1 operators in projects and unit testing to drive improvement in plant performance.

  • Participate in Unit HAZOPS and follow-up action items as required to mitigate risks in the unit from the PHA.

  • Maintain Unit Safety File updates relative to the MOC process and procedure. Maintain good PSM standards in the unit.

  • Participate in incident investigations and follow-up action items from incidents. This involves tasks such as chemical leak calculations and engineering corrective actions.

  • Performs equipment inspections during yearly turnaround activity and documents findings in equipment specific turnaround reports.

  • Utilizes knowledge of equipment and machine capabilities to develop action plan to increase the reliability of the unit. Recognizes problems and opportunities to formulate action plan(s)for obtaining/surpassing unit standards and achieving production and quality goals.

  • Compiles monthly / weekly reports as needed. An example of this is the weekly OEE report to management on status of the unit.

  • Provides support to operations personnel to troubleshoot day-to-day activities in the unit, and work closely with the Unit Supervisor and Unit Manager to effectively troubleshoot plant issues.

  • Provides support during absence of production Manager as needed.

  • Act as a steward for maintaining excellent HSSE performance in the unit - fulfill the HSSE Leadership Expectations.

  • Develops appropriate safety training for personnel regarding changes in procedures, and accountability.

  • Review all incidents in Incident/accident database and Safety Concerns.

  • Confers with water treatment vendor on a regular basis to ensure cooling tower, boiler feed water (both rental and waste heat) chemistries are properly maintained.

  • Works diligently to reduce variable expenditures of plant, primarily natural gas & Caustic consumption.

  • Champion WCM for the unit involving labeling of equipment and other visual management improvements.

  • Works with other units to ensure plant goals are met safely and effectively

  • Hold all employees accountable; including my peers, hourly employees, engineers and myself

  • Order raw materials (chlorine, polymer, etc.)

  • Incident report processing

  • Work with operators to keep al SOPs, EOPs, and COPs updated

  • Work with contractors and engineers in the unit; be involved in the projects as needed.

  • Housekeeping audits, weekly and have operators take care of any issues

  • Update operators daily instructions for needed guidelines to operate the unit

  • Attend 8:30 AM productions meeting and provide unit status. Communicate with loading area, TS, IFS, and customers as needed. Stay aware of and communicate as necessary, how unit operations will impact all other plant areas

  • Work with Manager to improve unit operations (efficiency, safety, costs, throughput)

  • Be professional and ethical at all times and treat employees, contractors and customers respectfully.

  • Other responsibilities as assigned by unit manager.


Minimum Qualifications:



  • 2 to 5 years in chemical processing

  • Engineering Bachelor's degree (B.S.) from four-year college or university; or equivalent combination of education and experience. (Chemical Engineering is preferred)



 

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