Process Development Engineer

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🏈 Alabama, Michigan, +3 more states – Remote

🏈 Alabama – Remote 🚗 Michigan – Remote 🤠 Texas – Remote ⚔️ Virginia – Remote ⛰️ West Virginia – Remote

⏰ Full Time

🟡 Mid-level

🟠 Senior

👷🏻‍♀️ Engineer

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Knauf Insulation North America

WebsiteLinkedInAll Job Openings

- employees

🏗️ Construction

🚀 Aerospace

⚡ Energy

Construction • Aerospace • Energy

Knauf Insulation North America is a leading manufacturer of insulation products and solutions, operating in over 40 countries with 29 manufacturing sites worldwide. The company specializes in a wide range of insulation solutions, including glass mineral wool, rock mineral wool, and wood wool, aimed at enhancing energy efficiency, fire safety, and acoustic comfort in buildings. Committed to sustainability, Knauf Insulation seeks to provide innovative solutions that contribute to better buildings and a greener planet.

📋 Description

• Drive the development, optimization, and standardization of white wool manufacturing processes and product quality across KINA plants • Serve as the divisional Subject Matter Expert for white wool manufacturing • Define and maintain standards for hot-end and cold-end white wool processes • Optimize spinner, fiberizer, forming, milling, transport, additive application, energy, and material consumption processes • Implement Lean, Six Sigma, and Continuous Improvement methodologies • Lead process trials and Design of Experiments, ensuring robust data collection and actionable insights • Partner with cross-functional teams to design and scale new processes, enhance process control systems, and improve reliability and output consistency • Provide hands-on technical support to KINA plants and resolve production challenges • Lead cross-plant troubleshooting for chronic losses using structured problem-solving tools • Collaborate with OEMs and suppliers to improve spinner performance, fiber quality, equipment life, and variability • Link field performance and quality data with production processes • Support plant construction, upgrades, modifications, commissioning, and start-up activities • Deliver training to develop white wool SMEs in each plant • Share best practices and governance mechanisms across KINA and KI plants • Document developments, maintain standards, and update training materials • Present recommendations and findings to management and stakeholders • Publish monthly dashboards covering performance trends, root causes, and process improvement opportunities

🎯 Requirements

• Degree in Engineering (Mechanical, Chemical, Electrical, or related technical field) required • Six Sigma Certification required; Green Belt minimum, Black Belt preferred • Minimum 5 years of experience in glass mineral wool manufacturing, covering hot-end and cold-end processes • Proven track record of project management and continuous improvement initiatives • Specific experience with white wool insulation production strongly preferred • Expertise in hot-end spinner/fiberizer and cold-end forming and milling process development • Strong knowledge of lean manufacturing, including 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 for influencing and training cross-functional teams • Proficiency with Minitab, MES systems, MS Office Suite, and data historian tools such as OsiPI • Strong project management skills, including cost-benefit analysis, milestone tracking, and stakeholder follow-up • Detail-oriented and results-driven • Ability to manage multiple projects in a dynamic, fast-paced environment • Requires 40% travel, with periods of higher travel during start-ups, commissioning, or major projects • Ability to occasionally lift up to 50 lbs. and work in varying plant environmental conditions, including dust and temperature

🏖️ Benefits

• Medical, Dental, Vision – starting on day one • Virtual Medical Services • Fertility and adoption benefits • 401(k) Retirement Plan with 100% matching on the 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) • Growth opportunities