Job Description:
JOB PURPOSE:
The Continuous Improvement Process Engineer drives measurable cost reduction, capacity improvement, and operational performance across pet food manufacturing operations. Utilizing Lean/Six Sigma methodologies and financial acumen, this role partners directly with plant operations to transform process inefficiencies into realized P&L savings, increased capacity, and improved yields. The position is responsible for developing and executing a pipeline of high-value continuous improvement opportunities, from initial opportunity identification and financial justification through implementation, validation, and sustained results - focusing heavily on extrusion, drying, packaging, and raw material utilization.
DESCRIPTION OF ESSENTIAL DUTIES:
Opportunity Identification & Analysis
Analyze manufacturing operations, conversion costs ($/lb, $/ton, labor hr/lb), and plant metrics to identify waste and process bottlenecks.
Evaluate focus areas including raw material giveaway, extrusion yields, dryer losses, bag/film packaging waste, utility consumption (steam, gas, power), and maintenance downtime.
Quantify potential savings into clear value buckets: Realized P&L Savings, Cost Avoidance, Capacity Expansion, Yield/Material Savings, and Labor Efficiency.
Pipeline Management & Project Development
Build and maintain a plant-wide Continuous Improvement Idea Library and submission process, establishing recognition (KUDOS) initiatives to foster an engaged continuous improvement culture.
Benchmark operational metrics across manufacturing lines and facilities to standardize best practices.
Translate prioritized opportunities into actionable capital expenditure requests (CERs), ROI business cases, timelines, and execution roadmaps.
Execution & Continuous Improvement Culture
Partner directly with plant managers, operators, and maintenance teams to execute improvement projects through influence, structured problem-solving, and root-cause analysis (8 Wastes of Lean).
Optimize core processing parameters, including extruder yield, dryer settings, coating application rates, and line throughput.
Conduct post-implementation tracking to verify financial savings on the P&L, ensure regulatory/food safety compliance, and establish sustainable standard work practices.
QUALIFICATION REQUIREMENTS: (To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or ability required).
Education & Experience: Bachelor’s degree in industrial, Manufacturing, Chemical, or Mechanical Engineering (or equivalent experience) with 5–7 years of hands-on manufacturing experience, preferably in pet food, food processing, or high-speed CPG operations.
Travel: Willingness and ability to travel up to 50% to support East Region plant facilities and assist in ongoing CI team projects.
Continuous Improvement: Proven expertise in Lean Manufacturing, Six Sigma tools (Green/Black Belt preferred), root-cause analysis, and systematic waste elimination.
Financial Acumen: Strong capability to connect engineering changes to financial metrics (P&L, capital planning, conversion cost reduction).
Technical Skills: Advanced Excel and data analysis capabilities; familiarity with extrusion, thermal processing, or bulk material handling is a strong plus.
Leadership & Communication: Track record of driving cross-functional alignment and leading site-level change without direct authority.
PHYSICAL DEMANDS: (The physical demands described here are representatives of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential function. The phrases “occasionally,” “regularly,” and “frequently” correspond to the following definitions: “occasionally” means up to 25% of working time, “regularly” means between 26…