Process/Continuous Improvement Engineer

Job Function: We are seeking a dedicated and experienced Process Engineer, Continuous Improvement to assess and continuously improve existing processes and lead the design, implementation, and optimization of innovative new production processes across our Illinois manufacturing facilities. supporting liquid, hot pour, and aerosol production lines. This role also carries lead responsibility for continuous improvement (CI) across both IL sites, including Lean and Six Sigma project leadership and CI-related KPI tracking and reporting. This role is hands-on and highly collaborative, requiring a balance of technical expertise, problem-solving ability, and cross-functional communication. The ideal candidate will have a strong background in chemical or mechanical engineering, experience with formulation technologies, and a solid understanding of manufacturing operations including compounding, mixing, hot pour, liquid filling, aerosol filling, milling, extrusion, and packaging.

Essential Duties and Responsibilities:

1. Manage the full lifecycle of process design and continuous improvement projects—from concept through to commissioning and startup.
2. Design, implement, and optimize new production processes with a focus on efficiency, safety, and quality.
3. Conduct process development, trials, validations, and optimizations to establish robust process parameters.
4. Source and evaluate equipment and process technology suppliers to meet project and process objectives.
5. Collaborate with cross-functional teams (innovation, operations, maintenance, quality, etc.) to align designs with business goals.
6. Troubleshoot process issues and provide technical guidance to resolve challenges.
7. Ensure compliance with safety standards, health regulations, and internal procedures.
8. Create and maintain technical documentation, including flow diagrams, reports, SOPs, and process specifications.
9. Assess and continuously improve existing processes for cost-efficiency, reliability, and scalability.
10. Contribute to the design, testing, and upgrading of equipment and process control systems.
11. Serve as the process engineering resource for both Illinois manufacturing facilities—Broadview and Blue Island—supporting liquid, hot pour, and aerosol production lines.
12. Lead continuous improvement (CI) initiatives across both IL sites using Lean and Six Sigma methodologies, including value stream mapping, kaizen events, and DMAIC-based projects.
13. Develop, track, and report key performance indicators (KPIs)—such as OEE, yield, scrap/waste rates, downtime, and cost savings—for liquid, hot pour, and aerosol processes to plant and executive leadership.
14. Identify, scope, and lead cost-reduction and efficiency projects, quantifying savings and presenting results to site and company leadership.
15. Partner with site leadership at Wireton and Parkes to standardize CI methodology, tools, and training across both facilities.

Minimum Knowledge, Skills, and Abilities:

1. Bachelor’s degree in chemical engineering, mechanical engineering, or a related discipline.
2. 3–5 years of experience in process design and engineering within a regulated manufacturing environment.
3. Proven experience across the full lifecycle of process design and continuous improvement projects (design, trials, commissioning, startup).
4. Strong background in chemical processes and formulation technologies (e.g., soap base-like materials).
5. Hands-on experience with process technologies such as compounding, mixing, extrusion, milling, hot pour, liquid filling, aerosol filling, and pressing.
6. Working knowledge of engineering design software.
7. Familiarity with process-related standards, safety requirements, and regulatory guidelines.
8. Strong technical, analytical, and problem-solving skills.
9. Excellent verbal and written communication skills.
10. Ability to manage multiple projects, prioritize tasks, and meet deadlines.
11. Demonstrated leadership in cross-functional environments.
12. Demonstrated experience leading Lean and/or Six Sigma continuous improvement projects with measurable results (e.g., cost savings, cycle time reduction, yield improvement).
13. Ability to develop, track, and report process- and CI-related KPIs to plant and executive leadership.
14. Willingness and ability to travel regularly between the Blue Island, IL and Broadview, IL facilities.

Preferred Qualifications:

1. Experience with process equipment maintenance and control systems.
2. Background in performing and documenting process qualifications and validations.
3. Lean Six Sigma certification (Green Belt or Black Belt).
4. Prior experience supporting aerosol filling/propellant systems in addition to liquid and hot pour operations.
5. Bilingual, Spanish/English speaking strongly preferred.