Process Improvement Engineer

Knauf Group; Canterbury-Bankstown; On-site; AUD 120,000 - 140,000; Full time

Benefits offered by this job

Phone & Laptop provided

14 weeks Parental Leave

Yearly Pay Review

Discounts on Health Insurance

Gym Memberships

Novated leasing and trade discounts

Free onsite parking

Free onsite Physio

Leadership development pathway

Job summary

Knauf Australia is seeking an experienced Process Improvement Engineer to support operational excellence through automation, reliability improvement and maintenance-focused process optimisation. This hands-on role requires a strong maintenance background, proven SAP experience, and a track record of resolving equipment and process issues before production is affected.

You will lead process optimization across plasterboard unit operations, drive OEE gains, and work closely with Production,

Qualifications

• 5+ years in engineering/process improvement/reliability/maintenance.
• Maintenance background in manufacturing/industrial environments.
• Strong automation and process control improvement experience.
• SAP knowledge, ideally in maintenance or engineering functions.
• Experience with root cause analysis (RCA) and breakdown analysis.
• Experience in heavy manufacturing or continuous process environments.
• Exposure to reliability-centred maintenance or asset-improvement programmes.
• Experience leading cross-functional improvement projects.
• Willingness to work on-site at Camellia Manufacturing site (not WFH).

Responsibilities

• Lead process optimization across plasterboard unit operations: calcination, mixing, forming line, drying, cutting, edge finishing, stacking and packaging.
• Improve OEE, reduce scrap, and shorten cycle times through data-driven problem solving and continuous improvement.
• Develop and maintain PFMEA, control plans, standardized work and work instructions.
• Apply Lean/Six Sigma tools (DMAIC, 5S, Kaizen, SPC, DOE) to address root causes and lock in gains.
• Partner cross-functionally with Production, Quality, Maintenance, Supply Chain, and R&D on NPI and product variants and scale-up.
• Drive automation and mistake-proofing; collaborate on controls/PLC improvements, recipe management, and real-time process monitoring.
• Plan and execute trials and validations; establish IQ/OQ/PQ and capability analyses where applicable.
• Champion a safety-first culture and ensure ISO 9001 compliance and site procedures.

Skills

5+ years experience

Maintenance background

Automation & process control

Cross-functional improvements

On-site work readiness

Education

Engineering degree or related discipline

Tools

SAP

Job description

More than 5 years' experience in a similar engineering, process improvement, reliability, or maintenance role

Demonstrated maintenance background within a manufacturing, industrial or processing environment

Strong experience in automation and process control improvement

Proven working knowledge of SAP, ideally within maintenance or engineering functions

Demonstrated experience in early intervention strategies breakdown analysis and failure root cause analysis

Experience in heavy manufacturing or continuous process environments

Exposure to reliability-centred maintenance or asset improvement programmes

Experience leading cross-functional improvement projects

Ability to work from the Camellia Manufacturing site full time - This is not a Work from Home Role

What you will need to join us

Full and Unrestricted Australian working rights - We do not offer visa sponsorship

Valid Police Check

Preferably, degree-qualified in Engineering or a related technical discipline

Successful completion of pre-employment medical

Why you will LOVE working at Knauf Australia!

$120,000 - $140,000 base salary + super

Phone & Laptop provided

14 weeks Parental Leave (primary carer)

Yearly Pay Review

Access to discounts on Health Insurance, Gym Memberships, Qantas lounge, Novated leasing and trade discounts

Leadership pathway: structured development, mentorship, and opportunities to lead visible, cross-functional initiatives

Free onsite parking

Free onsite Physio

About the Role

Knauf is looking for an experienced Process Improvement Engineer to support operational excellence through automation, reliability improvement and maintenance-focused process optimisation. This role is suited to a hands-on engineering professional with a strong maintenance background, proven SAP experience, and a track record of identifying and resolving equipment and process issues before they impact production.

Some tasks as part of this role include:

Lead process optimization across plasterboard unit operations: calcination, mixing, forming line, drying, cutting, edge finishing, stacking, and packaging.

Improve OEE, reduce scrap, and shorten cycle times through data-driven problem solving and continuous improvement.

Develop and maintain PFMEA, control plans, standardized work, and work instructions for stable, repeatable processes.

Apply Lean/Six Sigma tools (DMAIC, 5S, Kaizen, SPC, DOE) to address root causes and lock in gains.

Partner cross-functionally with Production, Quality, Maintenance, Supply Chain, and R&D on NPI, product variants (e.g., fire-rated, moisture-resistant), and scale-up.

Drive automation and mistake-proofing; collaborate on controls/PLC improvements, recipe management, and real-time process monitoring.

Plan and execute trials and validations; establish IQ/OQ/PQ and capability analyses where applicable.

Champion a safety-first culture and ensure compliance with relevant standards (e.g., ISO 9001) and site procedures.

About Us

Knauf is one of the world's leading manufacturers of modern insulation materials, gypsum wallboard systems, plasters and accessories, thermal insulation composite systems, floor screed, floor systems, and construction equipment and tools.

With more than 250 production facilities and sales organizations in over 90 countries, 40,000 employees worldwide. The Knauf Group is without doubt one of the big players on the market - in Europe, the USA, South America, Asia, Africa, and Australia.

Please note, applicants must have entitlements to work in Australia. As part of the recruitment process, police and medical checks for security clearance pertaining to specific job requirements will be conducted for successful applicants

We are committed to celebrating diversity and creating an inclusive environment. We encourage applications from people of all ages, nationalities, abilities, and cultures - including Aboriginal and Torres Strait Islander peoples, the LGBTQI+ community and people living with disability. Please let our team know if we can adjust our recruitment process to support your accessibility needs.