Process Engineer - Pet Food Company

Job Title: Process EngineerWork Location: Bay of Plenty, New ZealandJob SummaryWe are looking for a Process Engineer with strong analytical and problem-solving skills to optimize production processes, improve efficiency, and ensure product quality.
The ideal candidate will design, implement, and refine industrial processes to enhance productivity while minimizing waste, costs, and environmental impact.The Process Engineer will collaborate with cross-functional teams, including production, maintenance, quality assurance, and R&D, to drive process improvements and maintain operational excellence.Key ResponsibilitiesProcess Optimization & Efficiency Improvement:Evaluate existing manufacturing processes to identify inefficiencies and implement solutions to enhance performance.Utilize Lean Manufacturing, Six Sigma, and Kaizen methodologies to reduce waste and improve yield.Develop, configure, and optimize processes for increased efficiency, cost-effectiveness, and safety compliance.Conduct time and motion studies, workflow analysis, and bottleneck identification.Monitor and adjust production parameters to maintain process stability and product consistency.Equipment & Maintenance SupportWork closely with the maintenance team to ensure equipment uptime and reliability.Assist in troubleshooting and diagnosing failures in industrial machinery.Recommend modifications to improve equipment performance and longevity.Support the implementation of predictive and preventive maintenance programs.Evaluate new technology and automation solutions to enhance manufacturing capabilities.Quality Control & ComplianceEnsure that all processes comply with ISO, GMP, HACCP, FDA, OSHA, or other industry-specific regulatory requirements.Develop and implement process control plans (PCPs) to maintain product quality.Collaborate with the quality assurance team to analyze defects, deviations, and non-conformances.Lead investigations and root cause analysis (RCA) for process failures and deviations.Recommend and implement corrective and preventive actions (CAPA) for quality improvements.Data Collection & Performance MonitoringUse statistical analysis and process modeling software to track process performance and efficiency.Develop key performance indicators (KPIs) to measure process effectiveness.Maintain detailed process documentation, including Standard Operating Procedures (SOPs) and work instructions.Provide detailed reports on process performance, identifying areas for further improvement.Safety & Environmental ConsiderationsConduct risk assessments and implement safety protocols to minimize workplace hazards.Ensure compliance with environmental regulations and implement sustainability initiatives.Develop energy and resource optimization strategies to reduce operational costs and waste.Promote a culture of safety by training employees on best practices and process improvements.New Product Development & Scale-upSupport the introduction of new products by developing and refining manufacturing processes.Collaborate with R&D, engineering, and production teams to scale up pilot projects.Evaluate raw materials and alternative processing techniques for improved product performance.Project Management & Cross-functional CollaborationManage and execute process improvement projects from concept to implementation.Collaborate with supply chain, procurement, and logistics teams to optimize material flow and reduce lead times.Work closely with automation and IT teams to integrate Industry 4.0 technologies such as IoT, AI, and machine learning.Participate in cost-reduction initiatives and capital expenditure planning.Qualifications & SkillsEducational Background:Bachelor's degree in Chemical Engineering, Mechanical Engineering, Industrial Engineering, Manufacturing Engineering, or a related field.Master's degree (preferred but not required) in Process Engineering, Manufacturing Systems, or a related field.Technical SkillsStrong knowledge of process engineering principles, thermodynamics, fluid mechanics, and material science.Experience with CAD software (AutoCAD, SolidWorks) for process design and layout optimization.Proficiency in process simulation and modeling software (Aspen Plus, MATLAB, Minitab, ANSYS, or similar tools).Hands-on experience with PLC, SCADA, automation, and control systems.Understanding of Lean Manufacturing, Six Sigma (Green Belt or Black Belt certification preferred).Experience with CMMS (Computerized Maintenance Management Systems) such as Limble, SAP.Soft SkillsStrong analytical and problem-solving abilities.Excellent communication and collaboration skills to work with cross-functional teams.Project management experience with the ability to lead and drive initiatives.Detail-oriented with a proactive approach to identifying and mitigating risks.Preferred Experience3+ years of experience in process engineering in pet food or food manufacturing, or industrial operations.Industry experience in plastics, pharmaceuticals, food processing, chemicals, automotive, or heavy manufacturing is a plus.Familiarity with ISO 9001, ISO 14001, or other relevant certifications.Experience with energy efficiency projects and sustainability initiatives.Work Environment & ConditionsPrimarily on-site at a manufacturing or processing facility.Exposure to high-temperature environments, chemicals, and heavy machinery.May require occasional travel to supplier facilities, vendors, or other company locations.Involves hands-on troubleshooting and problem-solving in production settings.
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