Job Description

DSJ Global is currently partnered with a Consumer-Packaged Goods startup who is looking to add a Senior Process Engineer to their new facility outside of Lexington, KY. As Senior Process Engineer, you'll be responsible for enhancing production processes, troubleshooting operational challenges, and ensuring seamless scale-up of new formulas. The ideal candidate is a hands-on problem solver with deep experience in process engineering, particularly in liquid blending, solids blending, and substrate converting.

Responsibilities:

• Lead Process Design & Optimization: Develop, implement, and continuously refine processes for liquid blending, solids blending, and substrate converting to maximize efficiency and minimize waste.
• Scale Up New Products: Partner with R&D teams to transition new formulas and processes from lab-scale to full-scale production, ensuring smooth commercialization.
• Enhance Plant Operations: Oversee process troubleshooting, conduct root cause analyses, and drive operational improvements to enhance product yield, reduce downtime, and improve overall efficiency.
• Support Manufacturing Site Setup: Assist in establishing new production facilities, including equipment selection, commissioning, and scaling processes for high-volume manufacturing.
• Drive Data-Driven Decisions: Utilize process control tools such as value stream mapping, Pareto charts, and statistical analysis to identify inefficiencies and recommend improvements.
• Ensure Quality & Compliance: Maintain rigorous process documentation, including SOPs and batch records, while ensuring compliance with regulatory and safety standards.
• Train & Mentor Teams: Provide guidance to production staff and junior engineers, fostering a culture of continuous learning and operational excellence.
• Ensure Safety & Environmental Compliance: Uphold industry best practices for workplace safety and environmental sustainability across all plant operations.

Required Qualifications:

• Bachelor's degree in Chemical Engineering, Mechanical Engineering, Industrial Engineering, or a related field.
• Minimum of 5 years of experience in process engineering, specifically in liquid blending, solids blending, and substrate converting.
• Hands-on experience scaling up processes from lab-scale to full-scale production.
• Strong background in manufacturing site setup, equipment commissioning, and process optimization.
• Proven ability to troubleshoot complex process issues and drive efficiency improvements.
• Proficiency in process modeling, data analysis, and statistical tools (e.g., CPK, value stream mapping, Pareto charts, fishbone diagrams).
• Experience with Lean Manufacturing, Six Sigma, or other process improvement methodologies.

Preferred Qualifications:

• Master's degree in a related field.
• Lean Six Sigma certification (Green or Black Belt).
• Experience working with consumer goods manufacturing, home care, or chemical-based production.
• Familiarity with process automation and control systems.

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