Process Engineer

Job Purpose:

The Process Engineer is responsible for ensuring efficient, reliable, and cost-effective production processes within the dry mix mortar plant. The role focuses on optimizing plant performance, maintaining product quality, and improving process stability across raw material handling, drying, mixing, and packaging operations. The engineer works closely with production, quality, and maintenance teams to troubleshoot issues, implement continuous improvements, and ensure safe and compliant plant operations.

Key Accountabilities:

1. Process Optimization & Improvement

• Analyze and optimize production processes (raw material handling, drying, mixing, and packing).
• Identify process bottlenecks and implement corrective actions to maximize throughput and efficiency.
• Drive continuous improvement initiatives (Kaizen).
• Optimize formulation parameters to enhance product performance and cost reduction

2. Plant Operations Support

• Provide technical support to production/maintenance teams during daily operations.
• Troubleshoot process issues related to blending, dosing accuracy, moisture control, and material flow, filling bag, stacking and palletizing, sand fraction
• Monitor key process parameters such as:
• Temperature (dryer)
• Moisture content
• Mixing time and homogeneity
• Bulk density and particle distribution
• Bagging Machine cycle time
• Line speed
• OEE

3. Quality Control & Assurance

• Ensure production meets product specifications and quality standards.
• Collaborate with QC/QA team on testing protocols (e.g., compressive strength, adhesion, setting time).
• Investigate non-conformance issues and implement root cause corrective actions.

4. Process Design & Commissioning

• Participate in plant design, upgrades, and commissioning of new equipment.
• Evaluate equipment performance (mixers, dryers, conveyors, silos, dust collectors).
• Develop and update standard operating procedures (SOPs).

5. Material & Formulation Management

• Work closely with R&D to develop and improve mortar formulations.
• Evaluate alternative raw materials (cement, sand, additives) for cost and performance optimization.
• Manage raw material consumption and reduce waste.

6. Data Analysis & Reporting

• Monitor plant KPIs:
• Production efficiency (OEE)
• Yield and losses
• Energy consumption
• Use data analysis tools to drive improvement decisions.
• Prepare regular technical and production reports.

7. Health, Safety & Environment (HSE)

• Ensure compliance with HSE standards in plant operations.
• Identify process-related hazards and implement mitigation measures.
• Support safety audits and risk assessments.

8. Maintenance Coordination

• Work with maintenance team to ensure equipment reliability.
• Support preventive and predictive maintenance programs.
• Assist in root cause failure analysis (RCFA) for breakdowns.

Requirements:

• Bachelor’s Degree in: Chemical Engineering/Process Engineering/Mechanical Engineering/Material or Manufacturing Engineering
• Minimum 3–5 years of hands-on experience in manufacturing or process industries, preferably in: Drymix mortar production/ Cement, concrete, or building materials manufacturing/Powder processing or bulk material handling environment.
• Will be based in Bemban, Batu Gajah, Perak.