Operational Excellence Plant Process Engineer

Muenster Pet; Denton (TX); On-site; USD 85,000 - 120,000; Full time

Job summary

Muenster Pet in Denton, TX is seeking a Plant Process Engineer to lead lean transformation across production facilities and drive continuous improvement. This on-site role reports to the EVP of Operations and involves cross-functional collaboration to optimize processes and ensure safety and compliance.

The successful candidate will design and implement continuous improvement initiatives, develop KPI dashboards, and lead kaizen events while coaching teams to sustain gains and standard work

Qualifications

• Bachelor's degree in Engineering or related field, or 5+ years lean manufacturing experience.
• 3+ years hands-on experience implementing lean tools in manufacturing.
• Proven experience leading kaizen events and lean transformation initiatives.

Responsibilities

• Lead value stream mapping and eliminate wastes across production processes.
• Develop KPI dashboards and visual management systems to track improvement progress.
• Facilitate kaizen events and rapid improvement workshops with cross-functional teams.
• Design and implement standard work documentation and continuous improvement cycles.
• Lead TPM initiatives to improve equipment reliability and operator ownership.

Skills

Lean principles

Kaizen facilitation

Coaching

Gemba walks

Change management

Data analysis

TPM

Education

Bachelor's degree in Engineering

Associate degree + 5+ years lean exp.

Tools

Process mapping software

Microsoft Office

Job description

Muenster Pet has been dedicated to pet nutrition since 1932, starting in Muenster, Texas, and now headquartered in Denton, TX. With nearly a century of experience, we combine trusted ingredients with cutting-edge innovation, operating one of the most advanced freeze-drying facilities in the U.S. Our products, ranging from premium kibble to freeze-dried meals and treats, are carefully crafted to promote pet health and happiness. As leaders in private label co-manufacturing, we collaborate with brands and retailers across the country to deliver research-backed, innovative, and trustworthy products for pet parents.

Role Description

This is a full-time, on-site role in Denton, TX, for a Plant Process Engineer. The selected candidate will be responsible for improving and designing operational processes, ensuring efficiency and quality. Day-to-day tasks include analyzing existing workflows, implementing process control measures, and applying engineering principles to optimize production. Collaboration with various teams to identify improvement opportunities and ensure compliance with safety and regulatory standards will also be a core part of the role. This role will report into the EVP of Operations.

Duties and Responsibilities:

• Lead value stream mapping initiatives to identify and eliminate the eight wastes (muda) across production processes
• Establish and facilitate continuous improvement systems including suggestion programs and employee problem-solving teams
• Facilitate kaizen events and rapid improvement workshops with cross-functional teams (Operations, R&D, Maintenance, Quality)
• Develop KPI dashboards and visual management systems to track continuous improvement progress
• Implement 5S methodology and daily management systems throughout production areas
• Conduct time studies and takt time analysis to balance production flow and eliminate bottlenecks
• Design and implement standard work documentation with continuous improvement cycles built in
• Develop and track lean metrics including OEE, cycle time, changeover time, first-pass yield, and improvement project completion rates
• Lead SMED (Single-Minute Exchange of Die) projects to reduce changeover and setup times
• Implement pull systems and kanban for materials management and inventory reduction
• Facilitate daily tier meetings and continuous improvement huddles for operational accountability
• Train production teams on lean principles, continuous improvement tools, and problem-solving methodologies
• Conduct gemba walks to observe processes, coach employees, and identify improvement opportunities
• Manage capital improvement projects that support lean transformation with ROI justification
• Implement error-proofing (poka-yoke) solutions to reduce defects and rework
• Lead total productive maintenance (TPM) initiatives to improve equipment reliability and operator ownership
• Optimize plant layout and material flow to reduce non-value-added movement
• Develop A3 problem-solving documentation and track continuous improvement project pipeline
• Build continuous improvement capability through training, coaching, and recognition programs
• Establish improvement tracking systems to measure project impact and sustain gains
• Support OSHA, FSMA, HACCP, SQF, and SMETA compliance through lean process controls
• Travel between Muenster and Denton facilities to implement lean strategies and continuous improvement systems

MINIMUM REQUIREMENTS:

• Bachelor's degree in Engineering (Industrial, Mechanical, Chemical) or related field, OR Associate's degree with 5+ years progressive experience in lean manufacturing and continuous improvement implementation
• 3+ years hands-on experience implementing lean tools and continuous improvement systems in food manufacturing or similar industry
• Demonstrated success leading kaizen events, continuous improvement programs, and lean transformation initiatives
• Strong facilitation, coaching, and change management skills
• Comfortability in cold storage environment
• Experience working around raw meat and ingredients
• Valid driver's license and reliable transportation for multi-site travel

Knowledge, Skills, Abilities and Other Personal Characteristics:

• Expert knowledge of lean manufacturing principles, Toyota Production System methodology, and continuous improvement frameworks
• Proficiency with lean tools: VSM, 5S, TPM, SMED, standardized work, kanban, visual management, daily management systems
• Value stream mapping and process flow analysis expertise
• Root cause analysis using A3, 5-Why, fishbone diagrams, and Pareto analysis
• Strong coaching and mentoring abilities to develop lean thinking and continuous improvement culture in production teams
• Change management skills to overcome resistance and build sustainable improvement systems
• Data analysis and statistical process control for measuring improvement impact
• Project management including scope definition, timeline management, stakeholder communication, and improvement tracking
• Understanding of food processing operations including grain handling, extrusion, freeze-drying, and packaging
• Knowledge of GMP, food safety requirements, and sanitary design principles
• Excellent facilitation skills for leading kaizen events, continuous improvement workshops, and problem-solving sessions
• Strong written and verbal communication for training materials, standard work documentation, and management presentations
• Ability to influence and engage employees at all organizational levels in continuous improvement activities
• Proficiency with Microsoft Office Suite, process mapping software, and lean/continuous improvement tracking tools
• Self-motivated with ability to manage multiple improvement projects simultaneously across facilities
• Physical ability to spend extended time on production floor conducting gemba walks and coaching
• Flexibility to conduct training, kaizen events, and improvement activities across multiple shifts when needed
• Passion for developing people and building problem-solving capabilities throughout the organization
• Commitment to respect for people, continuous learning, and sustainable improvement principles