Process Improvement Engineer

Job Description

Auto req ID: 192671BR

Job Description

Process Improvement Engineer / Packaging (PIE)


This role involves maintaining, driving variation out of, and improving reliability in manufacturing operations specifically related to the Packaging of PET bottles. Successful Process Improvement Engineers have strong mechanical and process skills and a good working knowledge of control, logic and operational principles.

Objective:
The Process Improvement Engineer (PIE) is responsible for maintaining & improving manufacturing reliability, True Efficiency (TE), Running Efficiency (RE), production system capabilities, and operational stability.

Assignment:
The PIE works closely with Operations, Engineering & Maintenance to delivering improved results. The PIE delivers measurable improvements in Safety, People, Quality, Cost, and Productivity by identifying, leading, and owning results for TE / RE, LSS, etc. improvement plans and projects.

Technical Mastery:
a. The PIE develops mastery and understanding for the processes they are assigned to and uses that mastery to deliver improved TE, quality, yield, and thru-put. This includes understanding the physics and chemistry of how the production systems are designed to function, their limitations, and the impact of variation on thru-put, reliability, yield / cullage and quality.
b. PIEs are qualified in the following areas and are expected to use them to produce results.

  • Planned and unplanned downtime, rate, yield, and quality loss data collection methodology, analysis, interpretation and opportunity analysis
  • Loss analysis & TE improvement plan development, plan execution leadership, and results tracking
  • Centerline System management, including its development, maintenance & change management
  • Quality improvement process and quality validation
  • Rapid Changeover activities including principles, target setting, and leading successful efforts reducing changeover time to achieve challenging objectives
  • Analytical Troubleshooting & problem solving
  • Process Definition & Capability Studies c. PIEs are expected to have a working knowledge of the following areas, and build skills over time
  • Understand the fundamental tools & methodologies of the following TPM pillars – FI, AM, PM, EM
  • Product development testing
  • Early Equipment Management tools, methodologies, procedures & application
  • Package material evaluation / qualification process
  • CQV process – Commissioning, Qualification, Verification
  • OSHA, MSDS, GMP requirements, clean design
Specific Tasks:

a . Provide Weekly, Period, and ‘Year to Date’ reliability and variability downtime analysis support to the operation, including data analysis of results in such areas as TE, RE, and MTBF.
b. Apply reliability expertise to stabilize and improve the operation driving variation down and seeking improved TE through capital, procedural, and operational improvements in both planned and unplanned downtime areas.
c. Develop & Maintain Line Performance Boards covering planned and unplanned event frequency and duration, MTBF targets & results, Rate, Quality and Yield loss information, important variation analyses, production system Loss Trees, TE improvement plans and progress. Review and update on a weekly basis.
d. Develop, Own, and Manage the TE / RE Improvement Process for packaging and process, yield & cullage, and quality goals by production system.

This includes Weekly, Period and Year to Date results reviews incorporating:
  • Updated current and future state Loss Trees and Loss analyses
  • Production system target rates determination & speed mapping
  • TE / RE improvement plans, activities, progress, and tracking (development, maintenance and update)
  • TE / RE recovery plans for new products / system alterations expected to negatively impact

Qualifications/Requirements

  • BS Degree in Engineering, or related discipline required
  • 5 + years of manufacturing experience in a consumer products manufacturing operation
  • Ability to conduct assessments, audits and evaluation to measure progress
  • Solid problem solving and action planning skills
  • Must possess effective oral and written communication skills
  • Solid understanding of variable and period costs
  • Must be self-motivated, results and action oriented
  • Ability to make independent and sound decisions
  • Must possess solid interpersonal skills

Relocation Eligible: Not Eligible for Relocation
Job Type: Pipeline


All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, protected veteran status, or disability status.

PepsiCo is an Equal Opportunity Employer: Female / Minority / Disability / Protected Veteran / Sexual Orientation / Gender Identity

Our Company will consider for employment qualified applicants with criminal histories in a manner consistent with the requirements of the Fair Credit Reporting Act, and all other applicable laws, including but not limited to, San Francisco Police Code Sections 4901 - 4919, commonly referred to as the San Francisco Fair Chance Ordinance; and Chapter XVII, Article 9 of the Los Angeles Municipal Code, commonly referred to as the Fair Chance Initiative for Hiring Ordinance.

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