Process Development Engineer

Knauf Insulation is a rapidly growing manufacturer of acoustical fiberglass insulation for residential, commercial, industrial, marine, OEM, and metal building applications. The Process Development Engineer will serve as the divisional white wool manufacturing subject matter expert, optimizing and standardizing processes, supporting plants, leading trials and continuous improvement initiatives, and driving improvements in output, quality, reliability, and cost. The role also involves cross-functional leadership, technical training, plant start-up support, and stakeholder reporting.

Responsibilities:

• Define and maintain standards for white wool processes, including hot end (spinner, fiberizer) and cold end (forming, milling, transport, additive application, and collaborate on packaging)
• Optimize hot end processes, collaborate to enhance spinner designs, improve Fiberizer/forming technologies, and optimize energy and material consumption
• Implement Lean, Six Sigma, and CI methodologies to drive process capability, efficiency, and cost reduction
• Lead trials to optimize processes, manage DOEs (Designs of Experiment), ensure robust data collection, and deliver actionable insights
• Partner with cross-functional teams to design and scale up new processes, enhance process control systems, and improve reliability and output consistency
• Provide hands-on technical support to KINA plants, focusing on resolving production challenges and closing gaps in raw materials, forming, and packaging
• Convene and lead cross-plant troubleshooting for chronic losses using structured problem-solving tools
• Collaborate with OEMs and suppliers to improve spinner performance, fiber quality, and equipment life while reducing variability
• Link field performance and quality data with production processes, ensuring feedback loops improve manufacturing outcomes and customer satisfaction
• Support new plant construction, upgrades, and modifications, contributing deep expertise to commissioning and start-up activities
• Deliver a structured training program to develop white wool SMEs in each plant, ensuring ongoing local expertise
• Share best practices and governance mechanisms across KINA and KI plants to drive performance alignment
• Document all developments to protect intellectual property, maintain standards, and update training materials
• Present recommendations and findings to KINA management and key stakeholders
• Publish monthly dashboards outlining performance trends, root causes, and process improvement opportunities

Requirements:

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