Senior Process Engineer

POSITION TITLE: Senior Process Engineer

REPORTING TO: Senior Process Engineering Manager

LOCATION: Pennsauken, NJ

ABOUT THE COMPANY:

With annual sales of CHF 6.7 billion (EUR 6.22 billion / USD 6.91 billion) in fiscal year 2015/16, the Zurich-based Barry Callebaut Group is the world’s leading manufacturer of high-quality chocolate and cocoa products – from the origination and processing cocoa beans to producing the finest chocolates, including chocolate fillings, decorations and compounds. The Group runs more than 50 production facilities worldwide and employs a diverse and dedicated global workforce of over 9,300 people.

The Barry Callebaut Group serves the entire food industry, from industrial food manufacturers to artisanal and professional users of chocolate, such as chocolatiers, pastry chefs, bakers, hotels, restaurants, and caterers. The two global brands catering to the specific needs of these Gourmet customers are Callebaut® and Cacao Barry®. 

SCOPE AND RESPONSIBILITIES:

Job Summary:

This position combines process design, implementation/commissioning services and maintenance support of manufacturing processes and equipment and provides support and recommendation to specific needs and issues at the site.  Process improvement may include equipment specification, process design, and product development/improvement. Usage and implementation of continuous improvement principles, such as 5S, 8S and lean principles to focus on improving the outcomes of various processes. A process could be an actual industrial process (machines & products) or an information process.  The process improvement manager makes recommendation to improve the overall performance of the plant, either by increasing efficiency, or reducing cost and waste, or increasing employee and customer satisfaction.

Essential Functions:

• Identify improvement opportunities and define specific areas for improvement with the Site Manager to translate them into concrete projects. They are 3 main topics for possible : machines and process, product and general continuous improvement 

Machines and process: 

• Analyze process requirements and evaluates equipment and systems to ensure deliverables meet or exceed process specifications and manufacturing requirements. 
• Evaluate and recommend new process technologies that optimize performance, are cost effective, and will improve product quality, manufacturing techniques and safety. 
• Analyze trends to characterize scale-up and performance/functionality of processes and to improve product/process quality, consistency, productivity, efficiency, and risk levels. 
• Make observations and taking measurements directly, as well as collecting and interpreting data from the other technical and operating staff involved.
• Review existing data and reports to see if more research and information need to be collated, and assess the adequacy of the existing processes and equipment. Measure and systematize processes, reduce variations, defects, cycle time etc.
• Work with frontline staff, identifying improvement opportunities and coach/train employees on how to work more efficiently.
• Work with engineering project leaders and maintenance manager to define Capex and in sometime work on new equipment start-up.

Products 

• Analysis existing products and new product to define how eventually the recipes could be optimize for the plant efficiency. Participate to products specification reviews ( Prodcom)  
• Work closely with other specialists, such as R&D, QA (including: personnel responsible for the quality control of raw materials, intermediates and finished products) on trials 
• Interact in some cases with customers QA and or R&D to balance customers requirements vs. BC equipment feasibility

Continuous improvement:

• Lead and manage the continuous improvement program. Apply principles and tools of continuous improvement when possible. 
• Develop and measure standard metrics, diagramming the flow (including inputs and outputs) of our business process, identifying opportunities for improvement, developing a project plan for implementing improvements and monitoring the new process to ensure it provides desired results. Prepare relevant reports, flow diagrams, statistics and charts.
• Work with production staff to eliminate reoccurring customer complaints/ non-conforming product- operational errors/ standardize processes and increase first time yields.   
• Work with Production and Human Resources in the development of work instructions and training plans.
• Work with Plant Controller to ensure all operating trends are reflected in the financial indicators
• Work with the QA team to ensure all regulatory compliance.
• Ability to adhere to GMP practices and all other food safety requirements

JOB QUALIFICATIONS:

Requirements:

• Bachelor’s degree in Engineering (Food Science, Food Technology, Industrial Engineering or an equivalent field)  
• 5 years’ experience in the field of similar function/position – preferably a food manufacturing environment.
• Intermediate level skills with Microsoft Office software
• Experience with SAP 
• Bilingual an asset
• Requires occasional traveling
• Professional training or experience in project management and continuous improvement
• Proven ability to work independently and within time constraints
• Successful problem-solver and confident handling multifaceted aspects of a project
• Effective analytical and problem-solving skills – critical thinking
• Ability to lead a multidisciplinary group
• Knowledge of the transfer process
• Ability to develop an understanding of Barry Callebaut factory production capabilities
• Must be able to freely move around entire facility. 
• Exposure to noise, heat, cold and dust.

We are an equal opportunity employer and value diversity at our company. We do not discriminate on the basis of race, religion, color, national origin, gender, sexual orientation, age, marital status, veteran status, or disability status.