Process Improvement Engineer

Job Description

Auto req ID: 200666BR

Job Description

The Process Improvement Engineer (PIE) is responsible for leading the FI Pillar, maintaining & improving manufacturing reliability (TE), production system capability, operational stability/variability, develops solutions to repetitive failures, asset utilization (Speed Balancing), yield reduction, and Plant operational cost reduction. The PIE partners with Operations, TPM, Quality, Finance, and Engineering & Maintenance to deliver improved results through the process, capacity, quality, cost or regulatory compliance issues.

Technical Mastery /Tasks:

a. Develops mastery understanding for all processes and uses that 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. The PIE is expected to have a working knowledge of the following areas.

  • Skilled in the tools & methodologies of the following TPM pillars – AM, PM, FI, EM
  • Project Management Processes
  • Package material evaluation/qualification process
  • CQV process – Commissioning, Qualification, Verification
  • OSHA, MSDS, GMP requirements, clean design
  • LSS – Through GB training
  • Centerline System management, including its development, maintenance & change management
  • Rapid Changeover activities including principles, target setting, and leading successful efforts reducing changeover time to achieve challenging objectives.
  • Downtime Data Collection System – Data accuracy and Management
c. 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, MS, MTBF, and X-Matrix incorporating:
  • Unplanned Downtime MS event frequency & duration trend analysis
  • Unplanned MTBF and availability results and improvement plan
  • Loss analysis in the rate, quality and yield & cullage areas.
  • Production system target rates determination & speed mapping
  • TE improvement plans, activities, and progress (development, maintenance and update)
  • TE recovery plans for new products/system alterations expected to negatively impact TE.
d. Apply reliability expertise to stabilize and improve the operation driving variation down and seeking improved TE through the capital, procedural, and operational improvements in both planned and unplanned downtime areas.

e. Develop, Own, and Manage the TE Improvement Process for packaging and process, yield & cullage, and quality goals by the production system.

f. Ensure line event data systems are operating correctly with a high degree of accuracy. This includes the ‘Daily Management’ of the system, ensuring the systems are used to report accurate downtime data, timestamps are accurate, and alerting operations if system use falls below target levels. This also encompasses establishing and changing menus and reports, retrieving the database for analysis, analyzing data collected and interpreting results.

g. Support the Centerline System with AM teams, on changes to key process parameters, supporting visible plant centerline ‘health’ indicators is important.

h. Actively Participate in Production System Problem Solving for ‘Tough’ problems. The PIE becomes involved in problems requiring deeper penetration and expertise. This includes identifying and formulating the problem statement, developing potential solutions, prioritizing actions, determining and performing the appropriate analysis, and leading efforts through resolution.

i. Ensure efforts are integrated and support plant TPM efforts. The PIE is responsible to ensure the changes and modifications made are consistent with the AM, PM and other pillar efforts.

j. Lead the development of training material relating to TE, operational sequence of operation & the use of controls to regulate the process in achieving high TE / thru-put / quality.

k. Manage/support TE Improvement projects where the PIE can add unique value. Provide project management services for selected projects focused on improving the TE/availability/reliability/quality/yield of plant operations. They are, as any project manager, expected to complete projects within scope, at cost and on or before established timing.

l. Lead the FI pillar for the plant. Responsible to ensure plant personnel are trained and fluent in SRC and 7-step root cause analysis. Track and ensure completion/compliance with all FI triggers as well as ensure we get to the true root cause.

Qualifications/Requirements

  • Four years of technical or engineering degree required
  • Analytical, troubleshooting and problem-solving skills required
  • Strong organizational skills
  • Leadership and management skills required
  • Highly motivated, self-starter
  • Strong verbal and written communication skills
  • Financial knowledge required

Relocation Eligible: Eligible for Standard Relocation
Job Type: Regular


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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