Advanced Engineer, Production

Overview:

The Advanced Engineer - Production is responsible for providing technical and operational leadership to ensure the safe, reliable, and efficient operation of assigned manufacturing assets. This role serves as the primary technical resource for production operations, focusing on process optimization, loss elimination, equipment reliability, workforce capability development, and continuous improvement. The Manufacturing Expert partners closely with the 24/7 operations team, maintenance, engineering, quality, and stewardship resources to achieve Safety, Quality, Reliability, and Efficiency (SQRE) objectives while meeting production entitlement targets. This is an on-site role in Wilmington, North Carolina.

Responsibilities:

 

Process Performance & Operational Excellence

• Continuously monitor process, product quality, and equipment performance to detect and proactively address emerging issues.
• Lead efforts to minimize Operational and Scheduling Reliability (OSR) losses through data analysis, field observations, and structured problem-solving.
• Establish, communicate, and maintain operating parameters to ensure safe and efficient operation.
• Anticipate operational risks and implement strategies to maintain unit performance at entitlement targets.
• Identify and remove daily execution barriers in collaboration with the 24/7 operations team.
• Communicate issues that may impact production schedules, reliability, or product quality.

Technical Support & Troubleshooting

• Serve as the primary process and equipment expert for assigned production areas.
• Utilize field observations, PI data, operating data, and technical expertise to troubleshoot process and equipment issues.
• Participate in alarm management reviews and drive improvements in operating discipline.
• Support product changes, run-plan reviews, startups, shutdowns, outages, and operational transitions.
• Develop startup, shutdown, and outage strategies to ensure safe and efficient execution.

Asset Ownership & Reliability

• Maintain technical ownership of:
• • Line 2 production area
  • Associated process equipment and operating systems
• Maintain and continuously improve the Preventive Maintenance (PM) program, including:
• • PM task optimization
  • Frequency reviews
  • Addition or deletion of PM activities
• Conduct routine audits to ensure compliance with PM program requirements.
• Partner with Maintenance Gatekeepers, Production Engineers, and Reliability resources to prioritize equipment repairs and reliability improvements.

Root Cause Analysis & Continuous Improvement

• Lead and facilitate Root Cause Analysis (RCA) investigations.
• Ensure effective implementation and closure of corrective actions.
• Develop action plans when operational performance does not meet expectations.
• Track and drive completion of RCA action items.
• Lead initiatives that improve unit reliability, operating discipline, and production performance.

Safety, Compliance & Operating Discipline

• Champion safety and compliance through visible field leadership and routine field walkthroughs.
• Routinely evaluate site performance in:
• • Conduct of Operations (Con-Ops)
  • Energy Isolation (LOTO)
  • Safe Work Permitting
  • Equipment Opening and Line Breaking
  • Alarm Management
• Collaborate with operations teams to implement continuous improvement initiatives supporting safe and reliable operations.
• Stop unsafe acts or operating conditions when identified.
• Recommend shutdowns, delayed startups, or operating restrictions when safe operation cannot be assured.

Management of Change & Documentation

• Initiate and manage Management of Change (MOC) activities.
• Conduct field walkdowns to ensure proper implementation of changes.
• Develop and maintain Standard Operating Procedures (SOPs).
• Maintain and improve operating documentation, check sheets, operating limits, and process instructions.
• Provide technical rationale and documentation supporting operational changes.

Training & Workforce Development

• Develop and implement technical training programs for operations personnel and core team members.
• Build workforce capability through coaching, mentoring, and knowledge transfer.
• Create training strategies that strengthen process knowledge and operator effectiveness.
• Serve as a technical mentor and subject matter expert for production personnel.
• Partner with Learning Facilitators to enhance operational competence and technical expertise.

Quality & Stewardship Support

• Participate in quality investigations involving off-specification product.
• Support stewardship and environmental compliance initiatives.
• Ensure operating practices support product quality and regulatory requirements.
• Contribute to Tier 3 performance reviews and operational reporting.

Cross-Functional Collaboration

• Represent Operations on technical and capital project teams.
• Collaborate closely with:
• • 24/7 Team Captains
  • Production/process Engineers
  • Distillation Engineers
  • Stewardship Leaders
  • Daily Execution Leaders
  • Learning Facilitators
  • WTP/Utilities Specialists
  • Maintenance and Reliability Teams

Decision Authority

• Escalate issues that impact Safety, Quality, Reliability, or Efficiency performance.
• Gatekeep and enforce operational discipline related to alarms, manual operations, flooding events, and abnormal operations.
• Recommend shutdown or delayed startup of equipment or production units when safe operation cannot be maintained.
• Stop unsafe acts, conditions, or activities.
• Prioritize improvement and execution activities required to achieve SQRE objectives.
• Establish and maintain critical operating parameters for production systems.

Key Outputs

• Improved asset reliability and operational performance through RCA and action plan execution.
• Reduced OSR losses and improved production entitlement performance.
• Effective technical training and workforce development programs.
• Defined and maintained critical operating parameters.
• High-quality MOC documentation and implementation.
• Improved operating discipline and process safety performance.
• Optimized preventive maintenance strategies and equipment reliability.

Key Performance Indicators (KPIs)

• OSR Loss Reduction
• RCA Completion Rate
• RCA Action Item Closure
• MOC Action Item Closure
• Equipment Reliability Performance
• Process Safety and Operating Discipline Metrics
• Training Program Completion and Effectiveness
• Product Quality Performance

Qualifications:

• Bachelor's degree in Chemical Engineering, Mechanical Engineering, or related technical discipline; or equivalent manufacturing experience.
• 5 plus years of experience in a manufacturing, chemical, refining, petrochemical, or industrial environment.
• Demonstrated experience supporting continuous manufacturing or chemical processing operations.
• Strong understanding of production processes, equipment systems, and operational troubleshooting.
• Experience leading Root Cause Analysis and corrective action implementation.
• Working knowledge of Process Safety Management (PSM), Management of Change (MOC), and Conduct of Operations principles.
• Proficiency with PI systems, data analysis tools, and manufacturing information systems.