Overview

This role involves maintaining, driving variation out of, and improving reliability in manufacturing operations specifically related to the Packaging of PET bottles. Successful Process Improvement Engineers have strong mechanical and process skills and a good working knowledge of control, logic and operational principles

The Process Improvement Engineer (PIE) is responsible for maintaining & improving manufacturing reliability, True Efficiency (TE), Running Efficiency (RE), production system capabilities, and operational stability

Responsibilities

Assignment

The PIE works closely with Operations, Engineering & Maintenance on delivering improved results. The PIE delivers measurable improvements in Safety, People, Quality, Cost, and Productivity by identifying, leading, and owning results for TE / RE, LSS, etc. improvement plans and projects.

• The PIE develops mastery and understanding for the processes they are assigned to and uses that mastery to deliver improved TE, quality, yield, and thru-put. This includes understanding the physics and chemistry of how the production systems are designed to function, their limitations, and the impact of variation on thru-put, reliability, yield and quality
• PIEs are qualified in the following areas and are expected to use them to produce results
• Planned and unplanned downtime, rate, yield, and quality loss data collection methodology, analysis, interpretation and opportunity analysis.
• Loss analysis & TE improvement plan development, plan execution leadership, and results tracking
• Centerline System management, including its development, maintenance & change management
• Quality improvement process and quality validation
• Rapid Changeover activities including principles, target setting, and leading successful efforts reducing changeover time to achieve challenging objectives
• Analytical Troubleshooting & problem solving
• Process Definition & Capability Studies c. PIEs are expected to have a working knowledge of the following areas, and build skills over time
• Understand the fundamental tools & methodologies of the following TPM pillars - FI, AM, PM,
• Product development testing,
• Early Equipment Management tools, methodologies, procedures & application
• Package material evaluation / qualification process
• CQV process - Commissioning, Qualification, Verification
• OSHA, MSDS, GMP requirements, clean design

• Provide Weekly, Period, and 'Year to Date' reliability and variability downtime analysis support to the operation, including data analysis of results in such areas as TE, RE, and MTBF.
• Apply reliability expertise to stabilize and improve the operation driving variation down and seeking improved TE through capital, procedural, and operational improvements in both planned and unplanned downtime areas.
• Develop & Maintain Line Performance Boards covering planned and unplanned event frequency and duration, MTBF targets & results, Rate, Quality and Yield loss information, important variation analyses, production system Loss Trees, TE improvement plans and progress. Review and update on a weekly basis
• Develop, Own, and Manage the TE / RE Improvement Process for packaging and process, yield & cullage, and quality goals by production system

• Updated current and future state Loss Trees and Loss analyses
• Production system target rates determination & speed mapping
• TE / RE improvement plans, activities, progress, and tracking (development, maintenance and update)

• The expected compensation range for this position is between $72,500 - $121,300 based on a full-time schedule
• Location, confirmed job-related skills and experience will be considered in setting actual starting salary
• Bonus based on performance and eligibility; target payout is 8% of annual salary paid out annually
• Paid time off subject to eligibility, including paid parental leave, vacation, sick, and bereavement
• In addition to salary, PepsiCo offers a comprehensive benefits package to support our employees and their families, subject to elections and eligibility: Medical, Dental, Vision, Disability, Health and Dependent Care Reimbursement Accounts, Employee Assistance Program (EAP), Insurance (Accident, Group Legal, Life), Defined Contribution Retirement Plan

• BS Degree in Engineering, or related discipline required
• 5 + years of manufacturing experience in a consumer products manufacturing operation
• Ability to conduct assessments, audits and evaluation to measure progress
• Solid problem solving and action planning skills
• Must possess effective oral and written communication skills
• Solid understanding of variable and period costs
• Must be self-motivated, results and action oriented
• Ability to make independent and sound decisions
• Must possess solid interpersonal skills
• Systems Controls maintenance, troubleshooting and modification with Allen Bradley and Siemens systems, to include PLC's, VFD's, Communication networks Ethernet, RS232, and Device net