Process Improvement Engineer

Rigidal; Sydney; On-site; AUD 90,000 - 100,000; Full time

Job summary

Kingspan Insulated Panels is seeking a Process Improvement Engineer to optimise production lines, boost OEE, and standardise manufacturing practices in our Australian facility. You will lead Lean initiatives and drive automation projects, collaborating with Maintenance, Quality, and Engineering to enhance efficiency and reduce costs.

The role requires a bachelor’s degree in engineering, 3–5 years of manufacturing experience, and strong data analysis skills.

Qualifications

• Bachelor’s degree in Mechanical, Manufacturing, or Industrial Engineering.
• 3–5 years in manufacturing or process engineering.
• Strong process capability and data analysis skills.
• Experience with industrial automation and PLC/SCADA.
• Proficient in 3D modelling software (e.g., SolidWorks).
• Knowledge of SPC and continuous improvement methods.
• Experience with capital projects management.
• Experience in insulation panel or building products is a plus.

Responsibilities

• Analyse and optimise production processes for efficiency and OEE.
• Lead Lean and Continuous Improvement initiatives.
• Collaborate with Maintenance, Quality and Engineering.
• Support Industry 4.0 – real-time monitoring and data analytics.
• Assist with commissioning and upgrades of equipment.
• Support audits and ensure compliance with standards.
• Drive automation opportunities in manufacturing and inspection.
• Improve changeover times and production scheduling.

Skills

Lean Manufacturing

Continuous Improvement

Data Analysis

Project Management

Analytical thinking

Stakeholder engagement

Industrial automation

Power BI

SPC

Problem solving

Education

Bachelor's degree in Mechanical/Manufacturing/Industrial Engineering

Tools

PLC/SCADA

SolidWorks

Job description

We are seeking a Process Improvement Engineer to join our friendly, professional and highly driven team.

Working closely with Production, Maintenance, Quality and Engineering departments, this role will optimise continuous production lines, improve process capability, and standardise manufacturing practices to deliver safe, high-quality products while reducing operational costs.

Reporting to the Plant Manager, your main responsibilities will include:

Manufacturing Process Optimisation:

Analyse and optimise our production processes.

Improve line efficiency, throughput, and Overall Equipment Effectiveness (OEE).

Identify and eliminate bottlenecks to improve production capacity.

Improve changeover times and production scheduling flexibility.

Support the introduction of new manufacturing technologies.

Lead Lean Manufacturing and Continuous Improvement initiatives across the production facility.

Facilitate collaboration and cross-functional improvement workshops as required.

Assist Operations Management in promoting a culture of continuous improvement through employee engagement and training.

Work closely with Quality Assurance to reduce defects.

Improve compliance with product standards, customer specifications, and quality management systems.

Support internal and external audits, as required.

Automation and Digital Manufacturing:

Identify opportunities to automate manual production and inspection processes.

Support the implementation and optimisation of PLC- and SCADA-controlled production systems.

Work with Maintenance and Controls Engineers to improve machine reliability and automation performance.

Support Industry 4.0 initiatives, including:

Real-time production monitoring

Machine performance analytics

Digital work instructions

Automated quality data collection

Predictive maintenance

Assist with commissioning new production equipment and process upgrades.

Collaborate with Maintenance to improve equipment reliability and reduce unplanned downtime.

Analyse production losses and develop corrective actions to improve equipment availability.

Support preventative and predictive maintenance initiatives.

Participate in equipment upgrades and capital improvement projects.

About You:

Bachelor's degree in Mechanical, Manufacturing, Chemical, Industrial, Materials, or Process Engineering.

Minimum 3–5 years' experience in a manufacturing or process engineering environment.

Process capability and Data Analysis.

Experience with industrial automation.

Hands-on experience with 3D modelling software. Ex: SolidWorks

Excellent analytical, problem-solving, and project management skills.

Experience with managing Capital Projects.

Industry 4.0 Technologies

Experience in insulated panel, steel processing, building products, or continuous production manufacturing.

Knowledge of PIR foam processing, adhesive systems, or mineral wool manufacturing.

Experience with PLC/SCADA-controlled production lines.

Knowledge of Statistical Process Control (SPC).

Design and specifications, and commissioning of latest industrial technology.

PLC & SCADA Systems

Experience in Project Management

Power BI or similar reporting tools

Personal Attributes:

Strong analytical and systems-thinking skills

Results-oriented with a focus on operational excellence

Excellent communication and stakeholder engagement skills

Proactive and innovative approach to problem-solving

Strong organisational and project management capabilities

Collaborative and able to influence cross-functional teams

High attention to detail and commitment to quality and safety

What's in it for you:

Growing successful business

Employee reward and recognition program

Salary being offered is commensurate with qualifications and experience and is between $90,000 - $100,000 + super

About Us:

Kingspan Insulated Panels is a market leader in low-energy building envelope solutions. We manufacture single-component, factory pre-engineered systems for commercial customers across Australia, providing thermally efficient and fire-safe solutions.

Globally, we are part of the Kingspan Group, a world leader in high-performance insulation, flooring, rainwater harvesting solutions and building products. Our mission is to accelerate a net-zero emissions future, with the well-being of people and the planet at its heart.

If you’re ready to take the next step in your customer service career and join a team where you can make a real impact, we’d love to hear from you.

For more information about Kingspan Insulated Panels, please visit our website: https://www.kingspan.com/au/en