Process Engineer

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Merck Group is hiring a Process Engineer for its Lenexa KS Dry Powder plant, focused on blending, milling, dispensing, packaging, and equipment cleaning and drying. You’ll master the process, navigate control systems and OSI PI, support startup, mentor maintenance teams, and drive improvements in cycle time and quality using formal methods. The role requires a bachelor’s in Chemical or Bioprocess Engineering, with 1+ years in manufacturing in a regulated setting and familiarity with PLCs, OSI PI, and SPC Lean Six Sigma. On-call weekend support may be needed; sponsorship not provided; US work eligibility required. Apply by highlighting cross-functional leadership and data-driven improvements, and clear communication with operators and managers.

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This role does not offer sponsorship for work authorization. External applicants must be eligible to work in the US. 

Your Role:

The Process Engineer at the Lenexa, KS site, will play a crucial role in monitoring and supporting the Dry Powder Manufacturing process within our 24/7 media manufacturing plant. The Process Engineer will be responsible for gaining a comprehensive understanding of the Dry Powder Media manufacturing process, including blending, pin milling, dispensing/packaging, and the cleaning and drying of equipment. The incumbent will also navigate the process control systems for the equipment, ensuring a thorough understanding of how these systems interface and store data within the OSI PI historian. This role is essential for maintaining high-quality production standards and driving continuous improvement initiatives within the manufacturing environment. Job duties include:

• Knowledge of product powder attributes such as particle size, bulk density, flowability and cohesiveness.
• Liaison between maintenance, engineering, and the shop floor. Provide support and mentoring to other engineering and engineering support personnel.
• Assist in implementing process improvements and supporting equipment startup and commissioning activities.
• Provide technical support for process equipment and the manufacturing process to DPM personnel, including supervisors, lead operators, line operators, and internal departments or external customers as needed.
• Assess and implement process improvements for cycle time, quality, and safety, utilizing formal process improvement tools for large-scale enhancements.
• Larger scale projects will be managed formally, utilizing OSI PI data historian and analysis of existing process patterns to recommend improvements.
• Take part in and contributes to a safe working environment by following corporate and department safety regulations.
• Provide call-in and off-hour weekend support as required by projects, working independently across various shifts with flexible hours based on project execution needs.
• Performs other duties as assigned.

Physical Attributes:

• Lift 5 pounds continuously for up to six hours, with occasional lifting of up to 50 pounds as needed.
• Maneuver and position mechanical components up to 50 kg.
• Stand for long periods of time.
• Work within a controlled space without excessive perspiration.
• Report all medical conditions which could negatively affect the process/product.
• Pass a yearly physical exam. 

Who You Are

Minimum Qualifications:

• Bachelor’s degree in Chemical Engineering, Bioprocess Engineering, or other Engineering Discipline.

Preferred Qualifications:

• 1 + years of manufacturing experience in a regulated industry.
• 1+ years of project management experience.
• Proven ability to lead and participate as part of a team.
• Possess effective communication and customer service skills, with the ability to keep the Production Manager and other Process Engineers informed on all activities, interact productively with customers and co-workers, and work independently or as part of a team, while demonstrating strong written, oral, and presentation abilities.
• Proficient in MS Office Suite with some knowledge and ability to navigate Microsoft Access.
• Knowledgeable in navigating process PLC systems and OSI PI data historian.
• Knowledge of statistical process control methodologies, including Six Sigma, Lean Manufacturing, and SQC.
• Dry product processing and packaging experience

Pay Range for this position:  $78,000.00 - $125,200.00.

The offer range represents the anticipated low and high end of the base pay compensation for this position. The actual compensation offered will be determined by factors such as location, level of experience, education, skills, and other job-related factors. Position may be eligible for sales or performance-based bonuses. Benefits offered by the Company include health insurance, paid time off (PTO), retirement contributions, and other perquisites. For more information click here.

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