Process Development Engineer - White Wool

Knauf North America; Indianapolis (IN); On-site; USD 110,000 - 150,000; Full time

Benefits offered by this job

Medical + dental on day one

Virtual medical services

401(k) matching up to 100%

Paid parental leave

Paid family leave

Tuition reimbursement

Employee assistance program

Job summary

Knauf North America is seeking a Process Development Engineer to drive development, optimization, and standardization of white wool manufacturing processes across our plants. The role emphasizes leveraging CI, Lean, and Six Sigma to maximize efficiency, improve quality, and reduce costs.

The position requires a engineering degree and Six Sigma certification, with 5+ years in glass mineral wool manufacturing.

Qualifications

• Degree in Engineering (Mechanical, Chemical, Electrical, or related field).
• Six Sigma Certification required; Green Belt minimum, Black Belt preferred.
• 5+ years in glass mineral wool manufacturing; experience with white wool strongly preferred.

Responsibilities

• Define and maintain standards for white wool processes across plants.
• Optimize hot end processes; improve spinner and fiberizer tech; reduce energy and material use.
• Lead DOEs and trials; ensure robust data collection and actionable insights.
• Partner with cross-functional teams to design and scale up new processes; improve control systems.
• Provide hands-on technical support to KINA plants, resolving production challenges.

Skills

Lean manufacturing

Six Sigma

Project management

Leadership

Data analysis

Process optimization

Communication

Education

Engineering degree

Six Sigma Green Belt

Six Sigma Black Belt

Tools

Minitab

MES systems

MS Office

OSI PI

Job description

Knauf North America is the world's fastest-growing insulation manufacturer. We are wholly committed to the conservation of the environment while also sustainably developing and manufacturing a comprehensive line of acoustical fiberglass insulation for residential, commercial, industrial, marine, OEM and metal building applications, using post-consumer recycled materials.

We welcome passionate and creative individuals who thrive in an entrepreneurial, collaborative and ever-changing environment.

Our benefits go beyond just providing coverage.

We’re committed to the whole you – your health, wealth, peace of mind, self and community.

Our Benefits Include

• Medical, Dental, Vision – starting on day one!
• Virtual Medical Services
• Fertility and adoption benefits
• 401(k) Retirement Plan (earn 100% matching on your first 6% contribution and fully vested day one)
• Paid parental leave
• Paid family leave
• Company provided Salary Continuance (Short- term Disability)
• Company paid life insurance
• Paid Holidays
• Vacation
• Tuition Reimbursement
• Employee Assistance Program (EAP)
• Plus, more!

About The Role

The Process Development Engineer is responsible for driving the development, optimization, and standardization of white wool manufacturing processes and product quality across KINA plants, serving as the divisional Subject Matter Expert (SME) in this area. This role emphasizes leveraging engineering knowledge, white wool manufacturing experience, and Continuous Improvement (CI) methodology to maximize efficiency, overcome technical challenges, foster innovation, and share best practices. The position involves setting performance standards, supporting new and existing plant operations, and leading cross‑functional initiatives to deliver measurable results in output, quality, and cost reduction.

Candidates must be located within reasonable travelling distance of one of our plants.

• Shelbyville, IN
• Albion, MI
• Inwood, WV
• Lanett, AL
• McGregor, TX
• Shasta Lake, CA

What You'll Do

Technical Responsibilities

• Define and maintain standards for white wool processes, including hot end (spinner, fiberizer) and cold end (forming, milling, transport, additive application, and collaborate on packaging).
• Optimize hot end processes, collaborate to enhance spinner designs, improve Fiberizer/forming technologies, and optimize energy and material consumption.
• Implement Lean, Six Sigma, and CI methodologies to drive process capability, efficiency, and cost reduction.
• Lead trials to optimize processes, manage DOEs (Designs of Experiment), ensure robust data collection, and deliver actionable insights.
• Partner with cross‑functional teams to design and scale up new processes, enhance process control systems, and improve reliability and output consistency.

Process Support And Development

• Provide hands‑on technical support to KINA plants, focusing on resolving production challenges and closing gaps in raw materials, forming, and packaging.
• Convene and lead cross‑plant troubleshooting for chronic losses using structured problem‑solving tools.
• Collaborate with OEMs and suppliers to improve spinner performance, fiber quality, and equipment life while reducing variability.
• Link field performance and quality data with production processes, ensuring feedback loops improve manufacturing outcomes and customer satisfaction.
• Support new plant construction, upgrades, and modifications, contributing deep expertise to commissioning and start‑up activities.

Capability Building And Continuous Improvement

• Deliver a structured training program to develop white wool SMEs in each plant, ensuring ongoing local expertise.
• Share best practices and governance mechanisms across KINA and KI plants to drive performance alignment.
• Document all developments to protect intellectual property, maintain standards, and update training materials.

Reporting And Stakeholder Engagement

• Present recommendations and findings to KINA management and key stakeholders.
• Publish monthly dashboards outlining performance trends, root causes, and process improvement opportunities.

Education

• Degree in Engineering (Mechanical, Chemical, Electrical, or a related technical field) is required.
• Six Sigma Certification is required; Green Belt minimum, Black Belt preferred.

Experience

• Minimum of 5 years of experience in glass mineral wool manufacturing, focusing on both hot and cold‑end processes.
• Proven track record of project management and continuous improvement initiatives.
• Specific experience with white wool insulation production is strongly preferred

Knowledge, Skills, And Abilities

• Expertise in hot‑end (spinner/fiberizer) and cold‑end process development, including forming, and milling operations.
• Strong knowledge of lean manufacturing (SQDCP, Kata, Kaizen, LPA, DOE, and SPC).
• Proven ability to lead Six Sigma projects with annualized savings or measurable yield/output gains.
• Excellent leadership and communication skills with the ability to influence and train cross‑functional teams.
• Proficiency with Minitab, MES systems, MS Office Suite, and data historian tools like OsiPI for process insights.
• Strong project management skills, including cost‑benefit analysis, milestone tracking, and stakeholder follow‑up.

Other Requirements

• Must be detail‑oriented and results‑driven, committed to enhancing customer satisfaction through process excellence.
• Ability to manage multiple projects in a dynamic, fast‑paced environment.
• Requires 40% travel, with some periods of higher travel during start‑ups, equipment commissioning, or major projects.
• Must occasionally lift up to 50 lbs. and work in varying environmental conditions (dust/temperature) while in plants.

It is the policy of Knauf Insulation to provide equal employment opportunities to all qualified persons without regard to race, color, religion, sex (including pregnancy, childbirth, or related medical conditions), gender, sexual orientation, gender identity or expression, national origin, age, genetic information, disability, protected veteran status or any other protected characteristic prohibited by applicable law.

About Knauf North America

Knauf North America represents one of the most respected and progressive names in insulation worldwide. Though operations first began throughout Europe, Knauf Insulation manufacturing started here in the United States in 1978. Having since pioneered many sustainable insulation manufacturing practices, we are one of the fastest growing insulation manufacturers in the world.

Become part of the family you can trust — built on solid values and a diverse culture. At Knauf, you’re more than an employee. You’re part of the family. Part of something bigger. So we invest in you. Because you don’t just play a role in the building you’re in. You play a key role in impacting buildings globally. Doing good for the people within them and to make tomorrow a home for all of us.