Production Engineer

Position Title: Production Engineer

Position Summary

The Englewood site manufactures personal care ingredients and active pharmaceutical ingredients (APIs). Our operations include liquid and solid blending, encapsulation, milling, spray congealing, extrusion, and downpacking.

The Production Engineer owns day-to-day manufacturing performance at Englewood. This is a hands-on, floor-based role: working alongside operators, supervisors, maintenance, and quality to monitor processes in real time, solve problems at the root, and continuously improve how our equipment and our people perform. Englewood runs a mix of automated and manual operations, and a significant share of the work is still done by hand. A core part of this role is to learn those manual processes firsthand and bring innovative, practical solutions that improve safety, reduce labor load, and make our operations more efficient and consistent.

What Success Looks Like

Success in this role is process optimization grounded in real life on the production floor. The Production Engineer spends time with operators to understand how and why we do what we do, then applies sound engineering principles to make it easier for our people to be successful every shift. That work follows a simple cycle:

Understand. Spend time on the floor to learn each process, how it actually runs, and why it is done the way it is.

Measure. Collect data on real-life performance, including downtime, yields, cycle times, labor content, quality results, and near misses, rather than relying on assumptions.

Prioritize. Rank improvement opportunities by their impact on safety, quality, and productivity, and focus effort where it matters most.

Deliver. Facilitate the actions needed to bring improvements to life by aligning Production, Maintenance, Quality, and vendors, then follow through until results are sustained.

When this cycle is working, it shows up in our results:

Reduced downtime caused by unplanned events

Higher production performance through schedule adherence and Right First Time (RFT) manufacturing

Safer, less labor-intensive operations through targeted automation of manual tasks, with more efficient and consistent processes as a result

100% On Time In Full (OTIF) delivery with zero customer complaints, reflecting consistently high quality and reliable product stability

Essential Duties and Responsibilities

Key responsibilities include, but are not limited to, the following:

Daily process monitoring. Be on the production floor every day, observing and monitoring process performance across blending, encapsulation, milling, spray congealing, extrusion, and downpacking. Learn how and why each step is done, review batch records, process parameters, yields, cycle times, and in-process results, and act quickly on deviations before they affect product quality or the schedule.

Data collection and prioritization. Gather real-life data from the floor through observation, time studies, downtime and deviation records, and operator input. Maintain a prioritized list of improvement opportunities ranked by impact on safety, quality, and productivity, and review it regularly with site leadership.

Process optimization. Specify and run plant trials, and partner with R&D and technical service, to establish and tighten process parameters for safety, quality, throughput, and product stability. Translate results into updated batch instructions, SOPs, and operating windows.

Unplanned downtime reduction. Lead structured root cause analysis (5 Whys, fishbone, FMEA) on equipment failures, process upsets, and batch deviations. Partner with maintenance on preventive and predictive maintenance and critical spares, and track and trend downtime by cause to eliminate repeat events.

Schedule adherence. Work with planning and production supervision to identify and remove the constraints that keep the site from executing the schedule, including changeovers, cleaning, material staging, equipment availability, and staffing.

Right First Time. Identify and eliminate sources of rework, reprocessing, off-spec material, and documentation errors through robust process controls, error-proofing, and clear work instructions.

Understand the manual work. Learn manual operations firsthand by working alongside operators on tasks such as material charging, bag dumping, weighing, material handling, and downpacking. Map each process, measure labor content and variability, and identify the safety, ergonomic, and quality risks that come with manual handling.

Automation and innovation. Lead the site in finding and implementing innovative automation solutions, such as automated material handling and transfer, powder conveying, bulk bag unloading, automated weighing and dispensing, recipe-driven controls, and packaging automation. Build the business case for each opportunity based on safety, labor reduction, efficiency, and consistency, and see it through specification, vendor selection, installation, and startup.

People and standard work. Develop standard work, visual work instructions, and hands-on training for operators on new and existing processes. Bring operators into the design of improvements and automation so that solutions work on the floor, and support them through changes to their roles.

Quality and compliance. Support deviation investigations, CAPAs, and change control with Quality. Ensure processes meet cGMP expectations for API manufacturing (e.g., ICH Q7, 21 CFR 210/211) as well as personal care ingredient quality standards.

Customer focus. Support customer complaint investigations and connect process performance directly to customer outcomes. Monitor process capability on critical quality attributes so that product is consistent and stable lot after lot.

Facilitating action. Turn priorities into results by facilitating the actions needed across Production, Maintenance, Quality, Planning, and outside vendors. Set clear owners and timelines, remove roadblocks, and follow through until improvements are in place and sustained.

Performance metrics. Establish and maintain production KPIs, including unplanned downtime, OEE, schedule attainment, RFT, OTIF, and customer complaints, and review them in daily tier meetings and monthly operations reviews.

Continuous improvement. Apply Lean and Six Sigma tools (standard work, 5S, SMED, SPC, value stream mapping) to improve capacity, cost, and consistency.

Safety. Participate in PHA/HAZOP reviews and Management of Change, with particular attention to powder handling, dust hazards, and the ergonomic risks of manual operations.

Projects. Scope, justify, and execute capital and expense projects, including automation projects, that improve safety, reliability, capacity, and quality or reduce manual labor. Support commissioning, startup, and operator training on new or modified equipment, and work with Finance on budgeting and project close-out.

Note: The duties listed above are not all inclusive and may be subject to periodic updating or revision.

Education & Experience

Education: Bachelor of Science in Chemical, Mechanical, or Industrial Engineering. A minimum of 2 years of experience in a manufacturing environment, including at least 1 year in process or production engineering.

Experience:

Pharmaceutical or API manufacturing experience strongly preferred, including cGMP, batch records, deviations/CAPA, change control, and validation.

Experience in personal care, cosmetics, nutraceutical, food, or specialty chemical manufacturing is also valued.

Hands-on experience with one or more of the following: liquid or powder blending, encapsulation, milling/size reduction, spray congealing or spray drying, extrusion, or packaging/downpacking operations.

Experience implementing automation in a manufacturing environment, such as material handling, dispensing, controls, or packaging automation, is strongly preferred.

Lean or Six Sigma trai