The Sr. Process Improvement Consultant is recognized as a technical leader for PUR-MDI finished products, supporting the production train in the areas of improvement, investment, and process engineering. He or she manages continuous improvement of production and reliability processes, ensuring the appropriate level of technical support or problem solving such as failure analysis, defect elimination, and lean six sigma. The Improvement Consultant also manages the department project portfolio, supporting project development/prioritization and provides process engineering support to the production units. The Improvement Consultant will have typical targets such as project implementation schedule, asset performance, cost and other reliability centered / operational targets.
Major Tasks & Responsibilities:
Capital Investment Coordination:
- Manages the Improvement strategy for MDI finished products
- Maintains the RCA database including HSEQ incidents, MOE impacts, FAM costs drivers (including KPI 2-5), failure notifications (P-1, 2, 4 & 5), and quality issues
- Leads local RCA teams and supports global efforts, coordinating the resolution of technical issues within the assigned units, using troubleshooting, defect elimination, Lean 6 Sigma, etc… providing detailed reporting of causal factors and recommendations.
- Ensure timely completion of assignments within priorities established by supervision and manufacturing needs. Manage/influence other internal/external resources as needed to meet the time deadlines
- Tracks the implementation and effectiveness of corrective actions associated with RCA’s
- Coordinates tasks related to global reliability and continuous improvement programs (OEE tracking, energy effectiveness (E2), reliability and maintenance benchmarking (Solomon RAM), etc.)
- Mentoring of staff in improve capacity to maximize execution of RCA activities.
- Develop and support scope definition (specifications/deliverables), estimates, timelines, and project feasibility evaluations projects as generated by RCA corrective actions
- Supports Owner Representative (site PUR capital coordinator) for project portfolio management including prioritization and milestone requirements
- Develops investment documentation and manages the utilization of engineering for the initial stages of the Front-End Loading process.
- Manages projects as appropriate
- Responsible for development, maintenance and vitality of essential technologies and processes.
- Process modelling including mass/energy transfer and reaction kinetics
- Provides technical expertise to assessments, audits, investigations, incident reviews.
- Supports Process Hazard Analysis (PHA) and the Management of Change (MOC) process as needed.
- Possesses proficient knowledge of unit operations in Polyurethane (PUR) Manufacturing.
- Coordinates automation and advanced process control projects for the Baytown PUR area.
- BS Chemical or Mechanical Engineering or related degree with 10+ years’ experience OR
- MS Chemical or Mechanical Engineering or related degree with 8+ years’ experience OR
- PhD Chemical or Mechanical Engineering or related degree with 6+ years’ experience
- Accredited Lean Six Sigma Green-Belt Certification with completed project or ability and willingness to obtain certification (within 2 years of award of position)
- General knowledge of the manufacture of Aromatic Isocyanates and related derivatives and intermediates.
- Procedural knowledge of safety concepts for the manufacture of Aromatic Isocyanates and related derivatives and intermediates.
Financial Magnitude to describe the importance of the position
- Responsible for a FAM budget impacts ($4-7 MM) and CI budget ($1-5 MM) commensurate with an area replacement value $200-300 MM
- Single discipline projects <$1MM
Other non-financial Magnitude to describe the importance of the position:
Essential Knowledge and Skills:
- Knowledgeable in the existing process/facility technology and evaluate the application of emerging technology to improve reliability processes
- Maintain knowledge in field of expertise through external networking and/or global contacts
- Active participation in area, site, and global technology teams.
Candidate Must Have:
- Broad knowledge of reliability work processes to ensure license to operate as well as to improve reliability and FAM cost (i.e. mechanical integrity, asset strategy management, failure mode effects analysis, defect elimination, continuous improvement, life cycle management, and design for reliability).
- Working knowledge of process safety processes (i.e. process hazard analysis, pressure safety, management of change, pre-startup safety reviews).
- Broad knowledge of the capital process including but not limited to scoping, estimating, business case development, capital investment Front End Loading (FEL). A comprehensive knowledge of techniques, methods and best practices for the developing and management of capital investments portfolios.
- Knowledgeable in the financial concepts and tools e.g. budgeting, capital and expense investments, profitability analysis (i.e. discounted cash flow), creation, approval, and management Engineering Work Requests, work orders and requisitions.
- Knowledge of the effects of unit process conditions on mechanical reliability - i.e. reliability operating parameters/ windows/conditions process chemistry.
- Ability to obtain and analyze data from tools and systems used in chemical manufacturing (i.e. SAP, Meridium, Documentum, PI)
- Strong Oral and Written Communication Skills. Ability to communicate effectively within the unit team and with PUR site management.
For immediate consideration, please submit a recent resume in MS Word format in addition to a detailed cover letter with salary expectation.
- Bachelor degree (Chemical or Mechanical Engineering)
- 10 years experience
- Six Sigma Green Belt