R & D Process Engineer - Boksburg at RCL Foods

Purpose of the role: 

The R&D Process Development Department is critical in the development, design, and deployment of optimal, efficient and best in class processing design conditions including new pioneering / cutting-edge technologies for all innovation, renovation and Value Improvement Projects (VIP) / fuel for growth projects from pilot plant development phase to upscaling at factory scale across the different project gate phases: Concept, feasibility, capability, launch and post launch.

Key to this, is the development and adoption of processing design specifications and parameters that enable our factory to adhere to World Class Manufacturing Design and Operational Principles in supporting the growth ambitions of the business, beyond the current and future innovation funnel horizons. 

This means zero defects, zero waste, zero safety incidents and zero losses from product, process, technology design conceptualization to execution and post-launch monitoring and evaluation. Adherence and adoption of World Class Manufacturing methodologies such as Continuous Improvement/ Deming Wheel (PDCA), Focused improvement (FI) and Manufacturing Lean Six Sigma fundamentals is a key prerequisite to this role. At the core of a R&D process engineer’s job is providing process expertise to the business from a R&D lens focusing on product, process and manufacturing design; identifying and implementing process cost optimisation initiatives that impact on product, packing or manufacturing operations/ operability.

 
A key deliverable for the R&D Process Engineering role is driving the business Innovation Agenda through partnering with internal stakeholders such as Marketing/Brand Teams and Supply Chain Teams as well as external stakeholders such as growth partners /suppliers to deliver disruptive Innovation to the marketplace, Value Improvement Initiatives to drive accretive Gross Margin enhancement and new business opportunities that maximises our brand reach, presence and appeal. 

Minimum Requirements    
Education and Qualification

• BSc/ B. Eng Hons. – Chemical /Industrial/ Mechanical Engineering
• Project Management Qualification/ PMI Institute advantageous
• Lean Six Sigma (Yellow / Green Belt)

Experience and Training 

• 3 – 5 years minimum experience in Fast Moving Consumer Goods (FMCG) Industry, preferably a foods manufacturing and processing environment. 

Skills/Characteristic

• Attention to detail. 
• Critical reasoning. 
• Logical dedication.
• Solutions oriented. 
• Technical-mindset. 
• Stakeholder & People management. 
• Self Motivated and Driven. 
• Process Improvement mindset and Efficiency oriented. 

Problem Solving

• Use of information, data and knowledge to tackle complex business problems often with unknown variables into simplified business solutions.

Customer Relationships
Internal:

• Research and Development team. 
• Brand/ Marketing teams.
• Supply Chain Teams:
• Process Engineering team.
• Quality and Safety teams.
• Planning & Distribution teams.
• Production & Unit Managers.
• Engineering teams.

External:

• Ingredient, Process, Packaging and Technology Growth Partners/ Suppliers.
• Academia, Research Partners and Industry Institutions / bodies (CSIR etc.).

Decision Making

• Makes proposals to the R&D, Brand teams as well as the Innovation Executive Leadership team on the execution of innovation proposals that are aligned to the business growth strategy.

Leadership / Supervision 

• Leads teams in the execution of projects within the innovation space and in the manufacturing environment

Competencies

• Self-motivated, driven, action orientated individuals with ability to deliver through team and ensure effective communication with all stakeholders and team members

Communication

• Excellent written and verbal communication skills.
• Proficiency to conduct business proposals and influence other teams through effective communication skills and business jargon.

Duties & Responsibilities

• The key responsibility for this role within the R&D Process Engineering team is being the single point of contact for processing expertise from project ideation/ conceptualization to execution and deployment from feasibility to launch. This involves liaising with Marketing/Brand Teams regarding Innovation/ renovation brand strategies and liaising with Supply Chain teams from a manufacturing capability & capacity perspective in informing technical decision-making, gap analysis, project risk assessments/ risk charts and key jobs to be done at the beginning of the project lifecycle to ensure that all relevant inputs for the project are taken into consideration and are comprehensive/full encompassing. This implies being the technical project lead and focal point of contact for process-driven initiatives, innovations/ renovations, VIP /Fuel for Growth Projects. 

• R&D Process engineers are the custodians and owners of trial management process involving trial design, execution and reporting writing (objectives, trial KPI’s, trial risk assessment, trial cost consolidation, trial pre-alignments and actions, post-trial assessment, evaluation and reviews including trial report submission and close), Design Hazard Analysis Critical Control Points (D-HACCP) , Failure Mode Effects Analysis (FMEA), Hazard Analysis and Operability (HAZOP) Studies,  Quality by Design (QbD), Error/ Mistake Proofing (Poke Yoke Methodologies) including Quality Functional Deployment (QFD) are critical programs to this process. 

Key to the role is project management, risk management, Health, safety & ergonomics management, stakeholder management, budget management, project quality management and Project Change Management (Management of Change) to ensure that projects are delivered on time in full, within budget, quality & scope. 

She/he/they/them informs and manages CAPEX for projects related to innovations, renovations, VIP, Brand Lead Growth Projects, Cost Saving Initiatives, Process/ Quality/ Safety Enhancements leveraging pioneering technological design innovations. 

In addition, the R&D Process Engineering role also works in tandem with Supply Chain Process Engineers in the areas of process engineering expertise, communities of practice and excellence in providing troubleshooting support and problem solving. She/he/they/them provides knowledge and expertise in problem stratification, phenomena identification and problem statement outline/definition (5W+1H, 5W+2H), root cause analysis (4M/6M analysis, Cause and Effect Diagrams, Why-Why Analysis/ 5 – why analysis) and corrective measures/ preventative measures establishment. 

Activities and responsibilities include:

• Compiling Consolidated Technical Project Briefs for Innovation Projects.
• Capital Expenditure Proposals for Innovation Projects.
• Consolidation of Capital Expenditure Budget Spend Requests.
• Championing the Trial Management, Execution, Change Management and Handover Process.
• Leading d-Haccp, FMEA, QbD, QFD, HAZOP and Poke Yoke studies for innovation projects.
• End to End Project Management of Innovation and or Capex Innovation Projects across project life cycle.
• Working Knowledge of Material and Energy Balances (to incorporate energy efficiency design considerations and full appreciation of utilities impact throughout project lifecycle)
• Overseeing procurement and equipment pre-assembly, including leading FAT’s, Installation and commissioning, PAT’s, training, document handover and post launch review.

The R&D Process Engineer is responsible for validations and verifications pertaining to all process improvement initiatives proposed and implemented from innovation projects / new design considerations and or new technological improvements implemented at factory.