Process Development Engineer - White Wool

About the role

Knauf North America is looking for a Process Development Engineer to act as the divisional Subject Matter Expert (SME) for white wool manufacturing across its KINA plants. The role drives development, optimization and standardization of white wool processes and product quality, using engineering knowledge, manufacturing experience and Continuous Improvement methods to improve efficiency, quality and cost. It covers setting performance standards, supporting new and existing plants and leading cross-functional initiatives.

Key responsibilities

• Define and maintain standards for white wool processes, including hot end (spinner, fiberizer) and cold end (forming, milling, transport, additive application, packaging).
• Optimize hot end processes, spinner designs, fiberizer/forming technologies and energy and material consumption.
• Implement Lean, Six Sigma and CI methods to drive process capability, efficiency and cost reduction.
• Lead trials, manage designs of experiment (DOE), collect robust data and deliver actionable insights.
• Partner with cross-functional teams to design and scale up new processes and improve process control and reliability.
• Support KINA plants with production challenges, close gaps in raw materials, forming and packaging, and lead cross-plant troubleshooting of chronic losses.
• Work with OEMs and suppliers to improve spinner performance, fiber quality and equipment life.
• Link field performance and quality data with production processes, and support new plant construction, upgrades and commissioning.
• Train white wool SMEs in each plant, share best practices and document developments to protect intellectual property.
• Present recommendations to management, publish monthly dashboards and report on performance trends and root causes.

Required profile

• Degree in Mechanical, Chemical, Electrical or a related engineering field.
• Six Sigma certification (Green Belt minimum, Black Belt preferred).
• At least 5 years of experience in glass mineral wool manufacturing, covering hot and cold end processes.
• Proven project management and continuous improvement track record; white wool insulation experience strongly preferred.
• Ability to lead Six Sigma projects with measurable savings or yield gains.
• 40% travel, including higher travel during start-ups and commissioning; occasional lifting of up to 50 lbs in dusty, variable environments.

Required skills

• Lean manufacturing (SQDCP, Kata, Kaizen, LPA, DOE, SPC)
• Minitab, MES systems, MS Office and data historians such as OsiPI
• Cost-benefit analysis, milestone tracking and stakeholder follow-up

What we offer

• Medical, dental and vision coverage from day one, plus virtual medical services
• Fertility and adoption benefits, 401(k) with 100% match on the first 6% contribution
• Paid parental and family leave, salary continuance, life insurance and paid holidays
• Tuition reimbursement and Employee Assistance Program