Process Engineering Manager

Process Engineering Manager -- Biofermentation

Our process engineering manager is responsible for leading the process engineering team in support of Kerry Rochester’s safety, quality, production, cost, and maintenance goals. The process engineering manager also works closely with process technology and research and development on new product introductions and process optimization and with corporate engineering on capital projects exceeding $500k.

This role provides leadership and direction to the Rochester Process Engineering team, with responsibility for process optimization and supporting new product and process introductions from design through project installation and commissioning. The Process Engineering Manager will establish a strong, visible, and team-oriented technical focus. It is expected that the process engineering manager is the technical authority of fermentation, evaporation, and spray drying processes. A deep command of the engineering and scientific principles underpinning fermentation, evaporation, and spray drying is a core requirement of the role.

• ◆Leads the Rochester process engineering team to identify opportunities to improve equipment overall equipment effectiveness (availability – unplanned downtime, performance – fermentation kinetics, quality – solids target). The leader will create a continuous improvement focus through use of the scientific method to reduce process variability and lean manufacturing principles to eliminate the 8 forms of waste.
• ◆Apply deep knowledge in aseptic processing to identify and reduce sources of contamination and improve the reliability of processing steps. Partner with Engineering to design and implement improved process equipment as needed for new processes.
• ◆Development of appropriate capital plans to deliver business growth and cost efficiency ensuring alignment with the overall capital strategy for the business.
• ◆Conducts techno-economic analysis with technical feasibility studies including heat and energy balances and recommends the most cost-effective approach for development projects. Provides engineering support to R&D/process science activities during pilot and production trials.
• ◆Lead capital projects typically under $500k using traditional project management from project initiation/scope,

capture, design, cost estimation, equipment procurement, and installation with subcontractor management to meet scope, schedule, and cost. Responsible in assuring compliance with safety, environment, quality, and food safety. Assures that projects have detailed project specifications, process flow diagrams (PFD’s), piping and instrumentation drawings (P&ID’s), site and floor plans, elevation drawings, utilities matrices, and other project documentation, as applicable. Process engineering team typically supports corporate engineering who leads projects greater than $500k.

• ✓Process engineering team will lead the development of Standard Operating Procedures (SOP) that detail operations of new equipment and revises SOP’s to reflect changes to operations.
• ✓Leads elimination of systemic unplanned downtime events using continuous improvement tools and the 1 Kerry Plant System 8 step problem solving process to drive to root cause and eliminate future occurrences through corrective actions. Maintains the plant’s process failure mode and effects analysis that manages the plants highest risks in terms of severity, detection, and probability calculating a risk priority number to prioritize risk reduction actions.
• ✓Lead Kaizen events as needed to gather team of experts including the operators and production supervisors to solve large scale problems and also for conceptual design projects.
• ✓Promotes projects to reduce water, electricity, carbon burning fuels, and waste to meet Kerry’s sustainability targets.
• ✓Regularly explores new technology and equipment and subsequently develops projects to drive process improvement. Fosters a culture of process innovation with key partners in R&D, Quality, Operations and Finance. Key technologies include fermentation, sterilization, centrifugation, evaporation, spray drying, and packaging.
• ✓Leads team in accordance with the Kerry values and with a growth mindset to direct energy into identifying new solutions instead of wasting energy justifying why process improvements are not possible. Holds the team accountable to using the scientific method and making data-based decisions using statistics and lean six sigma tools such as gage R&Rs, hypothesis testing, capability analysis, design of experiments, etc.
• ✓Builds a high performing team through talent management that includes employee development, succession, and retention planning. May include 10-15% travel for benchmarking, development, and other Kerry plant support.

and skills

Minimum BS in Engineering with at least 10 years of engineering experience preferably in the food, chemical, or pharmaceutical industry.

Must have expert knowledge of manufacturing systems including fermentation, sterilization, spray drying, evaporation and associated sub systems such as refrigeration, wet scrubbers, high voltage power, electric motors/drives, standby power, fluid dynamics with pump/piping/filtration, programmable logic controller (PLCs), supervisory control and data acquisition systems (SCADA) and demonstrated aptitude to quickly