OPEX Process Engineer

BASIC FUNCTION

The Operational Excellence (OPEX) Process Engineer is responsible for continuous improvement, process optimization, operational reliability and operational business process standardization across the manufacturing units. This role combines engineering expertise with Lean/Six Sigma methodologies to enhance safety, quality, throughput, and cost performance. The engineer collaborates with operations, maintenance, technical, and leadership teams to implement sustainable improvements aligned with site strategic objectives.

RESPONSIBILITIES

• Performance management - Own OEE (overall equipment effectiveness), perform production loss tracking analysis, maintain performance metrics (KPIs) and report performance to leadership.
• Incident and risk management: root Cause Analysis (RCA) - Lead RCA investigations for events with a severity of 3 or higher with investigation support from the Production, Maintenance Technical, and HSSE teams. The role will establish the investigation team, schedule and lead investigation meetings, document the findings in the formal RCA report and coordinate and track the remediation process to completion.
• Bad Actor Analysis - Update Production Loss inputs to the Bad Actor Visual Management system. Ensure all Bad Actors are captured by the Production Loss list, Maintenance value list or Maintenance count list. Provide investigation and scope development work for Bad Actor projects.
• Management of Change (MOC) - Lead and coordinate complex MOCs (requiring engineering) to align the Production, Maintenance and Technical Project teams for CAPEX projects. Prepare project scope packages for submission to the CAPEX team.
• Align MOC/RCA actions with the Production, Maintenance, and Technical teams
• OPEX/standardization - Own, establish and maintain operational excellence meeting structures, systems and tools.
• Visual Management - Develop dashboards, KPIs, and data-driven insights for operations decision making. Implement and maintain the Baystar visual management system (huddle-board)
• Support Maintenance and Production in troubleshooting problems when needed
• Ensure a meeting cadence to conduct L2 Problem solving exercises to maintain continuous improvement by routinely investigating smaller events and using a work process that identifies and mitigates all causes
• Identify, document and communicate Lessons Learned for each turnaround and track implementation of mitigation measures identified for continual improvement
• Attend the morning Unit OPEX meeting. Ensure OPEX issues are identified, discussed and actions taken to mitigate problems and prevent recurrence
• Complete Safety & Loss Control responsibilities as required to achieve plant objectives. Conduct loss control tours as assigned. Report safety hazards that could cause harm to personnel and equipment.
• Stay current with product specifications, engineering technology and the production processes
• Provide technical guidance and expertise, identifying performance gaps and opportunities for improvement
• Position supports 24hr operation and may require overtime to meet plant needs and site deadlines
• Position requires on-call duty, and the ability to respond to plant emergencies on short notice, 24/7, 100% of the time, including nights, weekends, and holidays when on-call
• Train and coach personnel on OPEX principles and tools
• Perform other duties as assigned

CORE VALUES

Must exhibit and demonstrate our 4 Core Values

• Caring: Dedicated to Safety, Employees, Customers, Community and Environment
• Trustworthy: Living a Culture of Openness, Honesty and Collaboration
• Connected: Build Strong Partnerships
• Driven for Excellence: Commit to Continuous Improvement

COMPETENCIES

• Job Knowledge - Understands facets of job, aware of duties and responsibilities, keep job knowledge current
• Productivity - Manages workload, works efficiently, meets goals and objectives
• Quality - Strives to eliminate errors, accurate work is a priority, seeks opportunities to improve product/services
• Safety - HSSE - Works in a safe manner, uses PPE, recognizes hazards, makes safety suggestions and observations, current on Training Mine

QUALIFICATIONS / EXPERIENCE REQUIRED

• Bachelor's Degree in Chemical or Mechanical Engineering

(other technical degrees will be considered depending upon the experience level of the individual)

• 2-5+ years of experience in an engineering role
• Excellent verbal and written communication skills
• Ability to work independently and collaboratively in a team
• Ability to manage multiple priorities
• Proficient in MS Office
• Technical competence and process knowledge
• Experience with common operations processes
• Excellent planning, organization, and time management skills
• Process improvement skills

PREFERRED QUALIFICATIONS / EXPERIENCE

• Master's degree in Chemical Engineering from an accredited institution
• 5+ years of work experience in a petrochemicals environment
• 2+ years of work experience in Lean, Continuous Improvement or Operational Excellence
• Lean Six Sigma, Agile or equivalent qualification preferred
• Exceptional Computer literacy. Very strong skills in the use of word processing, spreadsheets, visual presentations, databases, data analytics tools, Power Query and Power BI
• Working knowledge of Distributed Process Control systems and Data Historians
• Working knowledge of the use and configuration of cloud based software packages
• Proficient in the use of SAP

PHYSICAL CAPACITY REQUIREMENTS

This position requires the incumbent to:

• Follow site safety requirements for the role and wear mandatory FRC and PPE (foot, head, ear, eye, hand, and fall protection) when inside plant environment or where directed by signage or procedure.
• Read, understand and develop technical documents and procedures in English.
• Specific vision abilities include near, far, and intermediate distances, color vision, peripheral vision, and depth perception.
• Required to work at ground level, from ladders, and from heights greater than 250' above grade on fixed platforms, mobile equipment platforms, and scaffolding.
• Ascend and descend stairs and stationary vertical ladders with and without a safety cage.
• Access confined spaces and pressure vessels through standard 24" manways.
• Must be capable of lifting/carrying/pushing/pulling up to 50 pounds.
• Frequent bending, reaching, stooping, crawling, walking, and climbing.
• Sit or stand for extended periods of time.
• Work at computer for significant periods of time throughout the day.
• Required to reach overhead and at shoulder level with hands and arms.
• Must demonstrate fine and gross motor coordination including pinching, gripping, turning, and keyboarding of both hands.
• Move about uneven surfaces, including catwalks, deck grating, and wet and muddy areas.
• Work outside in all weather conditions walking up to ½ mile per job.