Process Safety Lead

Kilgore Flares Company LLC; Toone (TN); On-site; USD 110,000 - 170,000; Full time

Job summary

Kilgore Flares Company LLC is seeking a Process Safety Lead to develop, implement, and continuously improve its PSM systems and Energetics Safety Programs. You will ensure regulatory compliance and partner with Operations, Engineering, Maintenance, and Quality to reduce risk and prevent major accidents.

Reporting to the Safety Manager, the role requires leadership in PHA, MAHRs, and risk assessments, along with cross-functional collaboration and strong communication skills.

Qualifications

• Bachelor degree in Engineering or related technical field; professional certifications in process safety may be considered.
• Experience in high-hazard manufacturing with PSM knowledge and regulatory familiarity.
• Strong problem-solving and analytical skills; able to interpret regulations and apply safeguards.

Responsibilities

• Maintain knowledge of US regulatory codes for explosives and pyrotechnics manufacturing (OSHA PSM, explosives regs).
• Establish and maintain documentation for process safety and HSE compliance policies.
• Lead Process Hazard Assessments (PHA) and track recommendations and corrective actions.
• Maintain MAHRs register alignment with regulatory requirements and corporate standards.
• Lead quantitative risk assessments (dust hazard, gas testing, risk contour mapping).
• Review PSI and maintain a compliant reference database.
• Collaborate with Asset Integrity & Reliability for proactive loss prevention monitoring.
• Develop internal process safety competency programs with Training/L&D.
• Lead or support investigations of high-hazard incidents and near misses.
• Audit PSM and HSE systems for compliance and continuous improvement.

Skills

Process safety

Regulatory compliance

Risk assessment

Cross-functional teamwork

Communication

Regulatory interpretation

Education

Bachelor of Science in Engineering / Process Safety

Tools

Microsoft Office

Job description

Description

JOB SUMMARY

The Process Safety Lead is responsible for developing, implementing, maintaining, and continuously improving Kilgore Flares’ Process Safety Management (PSM) systems and Energetics Safety Programs. The position ensures compliance with applicable regulatory requirements, corporate standards, and recognized engineering practices while partnering with Operations, Engineering, Maintenance, and Quality to reduce operational risk and prevent major accident hazards.

Reporting to the Safety Manager.

ESSENTIAL DUTIES AND RESPONSIBILITIES

• Maintain knowledge of the US regulatory codes and standards associated with explosives and pyrotechnics manufacturing including OSHA Process Safety Management (29 CFR 1910.119) and OSHA Explosives and Blasting Agents (29 CFR 1910.109), DoD Contractor Safety Manual (4145.26) and other relevant Recognized and Generally Accepted Good Engineering Practices (RAGAGEP) and consensus codes and standards (i.e. ANSI, NFPA, etc.).
• Establish and maintain documentation for compliance with group process safety policies and HSE framework
• Establish and maintain standard operating procedures for process safety and HSE compliance.
• Lead and facilitate Process Hazard Assessments (PHA) and maintain all associated documentation, including reporting and tracking of recommendations and corrective actions.
• Maintain ownership of the Business Unit Major Accident Hazard Risk Scenario (MAHRs) register, ensuring accuracy, periodic review, and alignment with regulatory requirements and corporate standards.
• Lead and facilitate quantitative risk assessments including dust hazard analysis, gas testing, risk contour mapping and other specialized process safety evaluations.
• Review relevant Process Safety Information (PSI) and maintain a database with appropriate references.
• Partner with Asset Integrity & Reliability team and support development of proactive loss prevention monitoring and facility status reporting, specifically as related to critical safety engineering controls.
• Partner with the Operational Trainer and Learning & Development Coordinator to establish, implement, and maintain internal standards for process safety competency, learning and development.
• Lead or support investigation of high hazard incidents and near misses, as directed. Ensuring identification of root causes and corrective actions.
• Lead and conduct audits of Process Safety Management (PSM) and Health, Safety, & Environmental (HSE) systems to verify compliance, evaluate program effectiveness, and drive continuous improvement.

OTHER JOB FUNCTIONS

• Comply with government and corporate laws, rules, regulations, policies, and procedures
• Ensure 100% compliance with the Chemring Operational Framework, Code of Conduct and U.S. Code of Ethics and Business Conduct.
• Special projects and other duties as assigned

SUPERVISORY RESPONSIBILITY

• Lead cross functional project teams and process safety initiatives
• Provide coaching and mentoring to Safety Technicians and other site personnel to strengthen process safety knowledge and foster a culture of operational excellence and continuous improvement.

EDUCATION/CERTIFICATION

• A Bachelor of Science degree in Engineering, Process Safety, Safety, Occupational Health or a related technical field preferred. Professional certifications and demonstrated experience in Process Safety Management within a high-hazard manufacturing environment may be considered.

EXPERIENCE

• Background in high hazard industry and loss prevention, preferably explosives manufacturing, however any PSM covered process would be expected as a minimum.
• Familiar with associated industry standards relating to high hazard facilities
• Proven track record for the determination of appropriate safeguards that meet the principles of RAGAGEP and As Low As Reasonably Practicable (ALARP)
• Ability to read process safety information and interpret its relevance for hazard assessment and safeguard development
• Knowledge of the relationship between asset integrity, maintenance and the status of safety critical barriers and engineering controls.
• Familiarity with different industry approaches to PHA such as FMEA, HAZOP, LOPA, Bow Tie, FTA or ETA

ADDITIONAL SKILLS AND QUALIFICATIONS

• Must be eligible to possess explosives under the Safe Explosives Act of 2003 (as amended) as required by the Bureau of Alcohol, Tobacco and Firearms (ATF)
• Must have strong organization and time-management skills to prioritize, delegate tasks and set goals for productivity
• Must be fully knowledgeable in state and federal regulatory compliance matters relating to safety and environmental matters
• Ability to collaborate effectively across the organization; cross functionally and at all levels
• Ability to read and interpret regulations and develop plans for implementation
• Excellent verbal and written communication skills as well as presentation skills
• Strong proficiency in Microsoft Office including Word, Excel, and PowerPoint
• Willing to work in an environment that requires a "Safety First" attitude. Must obey all Safety, Health & Environmental rules/regulations prescribed by regulatory agencies that are incorporated into company policy

PHYSICAL AND OTHER REQUIREMENTS

While performing the duties of this job, the employee is regularly required to handle energetic and non-energetic material. The position requires frequent, standing, walking, and sitting, with occasional reaching, climbing or balancing, stooping, and kneeling. The employee must regularly lift and/or move objects weighing up to 10 pounds, frequently lift and/or move objects weighing up to 25 pounds, and occasionally lift and/or move objects weighing up to 50 pounds.

DISCLAIMER

The preceding job description has been designed to indicate the general nature and essential job functions of this position. It is not designed to contain or be interpreted as a comprehensive inventory of all duties, responsibilities, and qualifications required of employees assigned to this job. Employees will be expected to perform other job functions and duties as may be needed and/or required.

EQUAL OPPORTUNITY EMPLOYER

Kilgore Flares Company LLC (KFL) is an equal opportunity employer. We evaluate applicants without regard to race, color, religion, sex, age, national origin, disability, veteran status, genetic information and other legally protected characteristics.

The "Know Your Rights" Poster is available here: EEO Know Your Rights

KFL EEO Policy Statement is available here: KFL EEO Policy Statement

Kilgore Flares Company LLC is committed to working with and providing reasonable accommodations to individuals with disabilities.

If you need a reasonable accommodation because of a disability for any part of the employment process, please send an e-mail to [e-mail] or call [phone] and let us know the nature of your request and your contact information.