Process Engineer

Carmeuse Lime & Stone Inc; Gary (IN); On-site; USD 120,000 - 150,000; Full time

Benefits offered by this job

Group medical/pharmacy insurance

Dental insurance

Vision insurance

401k with company matching

Annual Incentive Program

Wellness program

Life insurance

Disability insurance

Additional coverage

EAP

Referral bonus

Job summary

Carmeuse Lime & Stone Inc. in Gary, IN, seeks a senior operations engineer to own kiln and plant performance, drive process improvements, and ensure safety and efficiency.

You will lead refractory strategy, coordinate with maintenance and production, and drive continuous improvement across calcining, material handling, and quality. 5+ years in heavy industry engineering is required.

Qualifications

• Bachelor's degree in Chemical Engineering, Minerals Processing Engineering, Mechanical Engineering, or related fields.
• 5+ years' experience in an Engineering role within maintenance or operations.
• Experience in Root Cause Analysis and troubleshooting.
• Industry background in manufacturing related to mining, cement, lime, or similar heavy industry.

Responsibilities

• Owns operations strategy of the plant, directing production to meet KPI's.
• Owns refractory strategy and budget the plant, accountable for financial performance.
• Manages process capabilities of rotary lime kiln, Pulverizer Mill, and material handling systems.
• Monitors stone feed, calcining, lime quality, and inputs to production; drives improvements.
• Builds cross-group relationships to ensure communication and productivity.
• Oversees kiln process production efficiency and operator productivity.
• Ensures product quality and environmental compliance.
• Maintains a safe work environment in all duties.

Skills

Root cause analysis

Troubleshooting

Analytical skills

Communication

Initiative

Strong problem resolution

Education

Bachelor of Science in Chemical Eng/ Minerals Processing Eng/ Mechanical Eng

Tools

Industrial equipment knowledge

Job description

Tasks

• Supports company initiatives involving safety, digitization, and sustainability.
• Performs daily site safety walks and employee (safety) engagements.
• Identifies process barriers and bottlenecks, develops action plans, executes them, and assesses results.
• Establishes best practice Kiln Operating Guidelines, Standard Operating Procedures, and Operating Parameters.
• Creates and Communicates Daily Instruction Sheets in alignment with Kiln Operating Guidelines and Operating Parameters.
• Provides technical support to production, maintenance, environmental, and quality.
• Monitors reliability of the processes to define paybacks for improvements.
• Perform inspections during major outages of refractory, instrumentation, and prepare shutdown reports.
• Document problems related to the process or systems as seen or received from production. Reviews result with plant team to initiate, recommend, provide and/or implement solutions.
• Conducts process and energy audits to identify opportunities for improvement.
• Tracks and performs raw material analysis for the best use of the available fuels and stone conducting cost benefit calculations.
• Monitors stone quality, size and gradation, and fuel quality analysis and their impact on product quality.
• Trains operational personnel.
• Drives environmental compliance testing.
• Performs other duties as assigned.
• The execution of all duties and activities.

Responsibilities

• Owns operations strategy of the plant, giving direction to production of how to operate the kilns to meet production KPI’s.
• Owns refractory strategy and budget for the plant and is accountable for its financial performance.
• Managing the process capabilities of the rotary lime kiln, Pulverizer Mill, and other material handling systems on site.
• Monitoring, tracking, and continuous improvement of the stone feed system, calcining process, lime quality, and accuracy of all inputs to production, stone, fuels, additives, post-production packaging, etc.
• Building strong relationships with all groups within the site, region, and company to ensure seamless communication and productivity.
• Production, operational efficiency of the kiln process, and oversight of employee capability and productivity regarding the kiln process.
• Production consistency ensuring product quality and respecting environmental limits.
• Ensuring a safe work environment in the execution of all duties and activities.

Basic Requirements

• Qualified candidates will have a Bachelor of Science Degree in Chemical Engineering, Minerals Processing Engineering, Mechanical Engineering, or related fields.
• 5+ years' experience in an Engineering role within maintenance or operations.
• Experience in Root Cause Analysis and troubleshooting.
• Industry background in manufacturing related to mining, paper mills, steel plants, refractory, heavy equipment fabrication, stone processing, cement plants, rotary kilns, etc. Lime or cement experience is preferred.
• Qualified candidates will exhibit a positive and proactive attitude with high initiative and the ability to perform with minimal supervision.
• Able and willing to spend most of the time in the plant with the operators, maintenance personnel, and contractors; and able to communicate production and process plans effectively.
• Able to do limited travel to other sites and regions as needed.
• Good technical aptitude and analytical skills.
• Detail and process oriented with strong problem resolution abilities.
• Excellent communication and interpersonal skills.
• Must be able to support a continuous improvement environment as well as support change management initiatives.

Benefits Package Includes

• Competitive wages aligned with education and experience
• Group medical/pharmacy insurance options
• Dental insurance & Vision insurance
• A 401k account with company matching contribution
• Annual Incentive Program
• A robust Wellness program with financial rewards
• Company-paid life insurance and short-term and long-term disability insurance
• Optional Insurance to provide additional coverage
  Benefits Package Includes
  • Employee Assistance Program (EAP) at no additional cost
  • Employee Referral Program with bonus