Process Validation Engineer (m/f/d)

GAF Materials Corp.; Heusenstamm; On-site; EUR 70,000 - 100,000; Full time

Benefits offered by this job

Attraktives Gehaltspaket

Pensionsplan

30 Tage Urlaub

Arbeitsflexibilität

JobRad / Pendlerzuschuss

Kinderbetreuungszuschuss

Fortbildungsmöglichkeiten

Job summary

BMI Group sucht einen Prozessvalidierungsingenieur (m/f/d) am Standort Heusenstamm, der IQ/OQ/PQ-Protokolle schreibt, validiert und kritische Prozessparameter festlegt, um erstklassige Produktqualität sicherzustellen.

Sie arbeiten eng mit F&E, Instandhaltung, Continuous Improvement und Produktion zusammen, um Pilotphasen in die Großproduktion zu überführen und SOPs zu dokumentieren. Sehr gute Englischkenntnisse sind erforderlich; Deutsch von Vorteil.

Qualifications

• Abgeschlossenes Studium in einem relevanten Bereich (Chemieingenieurwesen, Polymerwissenschaft, Materialwissenschaft oder Maschinenbau).
• 3–5+ Jahre Berufserfahrung in Process Engineering oder Validierung in einer kontinuierlichen Produktion.
• Fließende Englischkenntnisse; Deutschkenntnisse wünschenswert.

Responsibilities

• IQ/OQ/PQ-Protokolle entwerfen, schreiben, ausführen und validieren.
• Kritische Prozessparameter festlegen und validieren, um Produktqualität sicherzustellen.
• Datenanalyse/DOE durchführen und Prozessfähigkeit bewerten.
• RCA und CAPA bei Abweichungen durchführen und dokumentieren.
• Engineering Change Orders managen und Re-Validierung sicherstellen.
• Zusammenarbeit mit R&D, Instandhaltung, CI und Produktion.
• Protokolle, SOPs und Zusammenfassungen erstellen.

Skills

IQ/OQ/PQ

Process validation

DOE

SPC software

5-Why

Fishbone

8D

CAPA

Education

Chemical Eng / Polymer Sci

Tools

Minitab

JMP

Job description

Vernetzen, Stärken, Entwickeln und Begeistern - das sind die Werte, die uns antreiben und die BMI zu einem Unternehmen machen, in dem Sie sich entfalten und wachsen können. BMI Group, a combination of Braas Monier and Icopal, is the largest manufacturer of flat and pitched roofing systems in Europe. With over 165 years of experience, BMI Group is the leader in roofing and waterproofing solutions throughout Europe, and has a significant presence in Asia and South Africa. Brands include: Braas, Bramac, Cobert, Coverland, Icopal, Klöber, Monier, Redland, Schiedel, Siplast, Vedag, Villas, Wierer and Wolfin. The name BMI is an abbreviation of the combined names Braas Monier Icopal and reflects our rich history of delivering roofing and waterproofing excellence to customers. Based at our Heusenstamm location, we are seeking a Process Validation Engineer (m/f/d) for our Manufacturing & Process Engineering (MPE) team within the Membranes division. In this role, you will oversee and execute process validation activities across our single-ply synthetics and bitumen roofing membrane manufacturing operations. You will lead IQ/OQ/PQ protocols, establish critical process parameters, and drive process capability to ensure our continuous production lines consistently adhere to top quality standards and operational metrics.

Your key responsibilities:

• Protocol Execution: Design, write, and execute Installation, Operational, and Performance Qualification (IQ/OQ/PQ) protocols for continuous extrusion and bitumen production lines.
• Process Optimization: Establish and validate Critical Process Parameters (CPPs) to guarantee consistent product properties (e.g., thickness, tensile strength, seam integrity).
• Data & Statistical Analysis: Evaluate manufacturing data using software like Minitab or JMP to assess process capability, determine operational windows, and conduct Design of Experiments (DOE).
• Problem Solving & Quality Assurance: Drive Root Cause Analysis (RCA) and implement Corrective and Preventive Actions (CAPA) for any out-of-specification deviations.
• Change Management: Manage Engineering Change Orders to ensure any modifications to machinery or formulations are properly re-validated.
• Cross-Functional Teamwork: Partner with R&D, Maintenance, Continuous Improvement, and Production teams to transfer new formulations from pilot phases to full-scale production.
• Documentation: Draft clear technical protocols, summaries, and Standard Operating Procedures (SOPs).

Your Profile:

• Education: Bachelor, Master, or Ph.D. in Chemical Engineering, Polymer Science, Materials Science, Mechanical Engineering, or a related discipline.
• Professional Experience: 3–5+ years of process engineering or validation experience in a continuous manufacturing environment 10+ years.
• Industry Focus: Strong preference for backgrounds in plastics extrusion, polymer film processing, calendering, or flexible web-handling systems.
• Technical Knowledge: Deep understanding of film/foil production, coating processes, and standard processing equipment (extruders, calendars, mixers).
• Methods & Tools: Proven proficiency in IQ/OQ/PQ methodologies, structured problem-solving (5-Why, Fishbone, 8D), and statistical process control (SPC) software.
• Advantageous Skills: Lean/Six Sigma (Black or Green Belt) qualification, knowledge of AI-based tools, thermoplastics extrusion, and bitumen processing. Experience in quality systems.
• Soft Skills: Strong ability to communicate complex technical data across different departments, from machine operators to plant management.
• Languages: Fluent in English; German language skills are a plus.

What we offer:

• based on hiring location it would include a range of the following: Future-Proof Compensation: Attractive salary package & company pension scheme
• Work-Life-Balance: 30 days of vacation, flexible working hours & primarily office-based work with a regular mobile office option
• Diverse Mobility Solutions: Job bike (JobRad), commuting allowance & free parking
• Support for Families: Childcare cost subsidy & pme Family Service
• Focus on Further Development: Individual development and training opportunities
• Health Matters: Health benefits & BMI supplementary health insurance fund (Zuschusskasse)

If you have any questions beforehand, please feel free to reach out to [e-mail].

BMI Deutschland GmbH Frankfurter Landstr. 2-4 61440 Oberursel

Vernetzen, Stärken, Entwickeln und Begeistern - das sind die Werte, die uns antreiben und die BMI zu einem Unternehmen machen, in dem Sie sich entfalten und wachsen können. BMI Group, a combination of Braas Monier and Icopal, is the largest manufacturer of flat and pitched roofing systems in Europe. With over 165 years of experience, BMI Group is the leader in roofing and waterproofing solutions throughout Europe, and has a significant presence in Asia and South Africa. Brands include: Braas, Bramac, Cobert, Coverland, Icopal, Klöber, Monier, Redland, Schiedel, Siplast, Vedag, Villas, Wierer and Wolfin. The name BMI is an abbreviation of the combined names Braas Monier Icopal and reflects our rich history of delivering roofing and waterproofing excellence to customers. Based at our Heusenstamm location, we are seeking a Process Validation Engineer (m/f/d) for our Manufacturing & Process Engineering (MPE) team within the Membranes division. In this role, you will oversee and execute process validation activities across our single-ply synthetics and bitumen roofing membrane manufacturing operations. You will lead IQ/OQ/PQ protocols, establish critical process parameters, and drive process capability to ensure our continuous production lines consistently adhere to top quality standards and operational metrics.