Senior Process Improvement Engineer – Manufacturing & Automation

Knauf Australia; Sydney; On-site; AUD 120,000 - 140,000; Full time

Benefits offered by this job

Phone & Laptop provided

14 weeks Parental Leave (primary carer

Yearly Pay Review

Discounts on Health Insurance

Gym Memberships

Qantas lounge access

Novated leasing

Trade discounts

Leadership pathway

Free onsite parking

Free onsite Physio

Job summary

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

You will lead cross-functional improvement projects on a site in Camellia, with opportunities to shape safety, quality and efficiency

Qualifications

• More than 5 years of experience in engineering, process improvement, reliability or maintenance.
• Hands-on maintenance background in manufacturing, industrial or processing environments.
• Strong experience in automation and process control improvement.
• Proven working knowledge of SAP in maintenance or engineering functions.
• Experience with early intervention strategies, breakdown analysis and 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.

Responsibilities

• Lead process optimization across plasterboard unit operations: calcination, mixing, forming line, drying, cutting, edge finishing, stacking, 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 scale-up.
• Drive automation and mistake-proofing; collaborate on controls/PLC improvements, recipe management and real-time monitoring.
• Plan and execute trials and validations; establish IQ/OQ/PQ and capability analyses.
• Champion safety-first culture and ensure ISO 9001 and site procedures compliance.

Skills

Process improvement

Automation

Maintenance

Cross-functional collaboration

Problem solving

Education

Engineering degree or related discipline

Tools

SAP

PLC programming

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
  
  

About You

• Located in or near Camellia
• 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.

Next Steps

If you would like to be considered for the position, please click "apply” and Shortlisted applicants will be contacted by a member of our talent team.

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.

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

We offer an opportunity to be part of a global family of over 40,000 high-performing people in 96 countries, who are dedicated to the same core values, and to a shared sense of purpose.

We encourage all our people to shape their own career, pro-actively building their future with the freedom to stretch their skills and to learn new ones.