Senior Process Engineer
Corning Incorporated 204 reviews - Manassas, VA

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Participate in the design, installation, start-up, operation, maintenance, or ongoing improvement of bio-manufacturing and pharmaceutical manufacturing processes and facilities.
Develop Functional Requirement Specifications (FRS) from design P&IDs for new processes; Design, specification, and procurement of equipment; Technical transfer of processes from development into commercial scale production; Training of production personnel associated with new process transfer; Collaboration with manufacturing support groups in the planning, reviewing, performance, and scheduling of activities related to start up of new processes; Support equipment installation, start-up, and validation activities.
Senior Level Process Engineer has responsibility for planning and executing the overall task, as well as leading cross-functional teams and communicating project status with individuals outside of the department.

Essential Duties and Responsibilities (Include the following. Other duties may be assigned)
Competence in Technical Field (Design, Installation & Operations)

Advises on commitment of resources (cost and schedule). Designs and develops sequence, layout, and arrangement of operations necessary for a project (new process, process scale-up, or revision to existing process). All designs are created with a number of factors in mind, including: Incorporate GMP principles, Develop everything so that it is feasible, robust, and within budget and Design for waste management minimization. Creates blueprints, P&IDs, and process flow diagrams. Simulates process operations on computer. Calculates material/energy balances. Designs, specifies, and procures equipment as well as investigating alternative equipment configuration of existing equipment. Develops Functional Requirement Specifications (FRS) from design P&IDs for new processes. Develops user requirements for new processes. Develops CIP or SIP protocols for new processes. Scales up the process to pilot and manufacturing scale. Conducts safety or HAZOP (hazard and operability) reviews of a process in order to identify potential hazards and operability problems caused by deviations from the design intent of both new and existing process plants.
Manages installation, validation, and start-up activities. Writes and submits change control documents. Assists in developing and executing Commissioning/Qualification/and Validation protocols for new equipment. Typical protocols include: Factory acceptance test (FAT) procedures, Validation master plan System-commissioning protocols & Validation protocols Installation qualification (IQ), Operation qualification (OQ) and Performance qualification (PQ) Determines and orders raw materials for commissioning and validation. Identifies alternate vendors/suppliers. Writes operation qualification and process qualification test plans. Performs dry runs of automation sequences (Site Acceptance Testing or SAT). Performs equipment qualification protocols including automation control. Writes SOPs for equipment operation. Walks down P&IDs and isometric drawings for installation verification and drawing accuracy. Develops batch records. Develops preventive maintenance (PM) and calibration schedules. Creates and revises construction punch lists. Signs-off and accepts facility and equipment. Performs start-up training on equipment. Determines spare parts requirements.
Collaborates with manufacturing support groups such as Operations, Validation, Engineering/Facilities Engineering Services, and Instrumentation/Calibration Services in the planning, reviewing, performance, and scheduling of activities related to start up of new processes and support of existing processes. Supports and defines PVRs (Process Validation Runs). Investigates process, equipment, and automation deviations (ongoing troubleshooting). Performs process improvement functions including: bottleneck analysis activities to improve robustness technology transfer from process development Performs activities related to process control such as data trending, maintenance and automation changes, and control scheme updates, and monitors product quality (e.g. particle-size distribution of a granulated product). Performs activities related to change control such as identifying potential change, design and pre-approval of changes, implementation, required regulatory submissions, validation, and ROI analysis. Performs activities related to shutdown (and subsequent startup). Assists in emergency maintenance and monitors frequent/repeat maintenance repairs. Designs experiments to optimize and improve the process.

Intermediate Project Management Skills & Practices Organizes and manages large and/or complex projects to ensure efficient use of resources and effectively deliver results that meet or exceed expectations. Is also able to prioritize and coordinate multiple priorities simultaneously. Recommends total plan contingencies and alternatives to achieve project (technical and economic) objectives for their discipline. Manages and/or supports cross-functional teams. Writes proposals, reports, and regulatory submission packages for projects. Determines solutions to technical problems. Secures and protects intellectual property.
To perform this job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions. Must have proven experience with Allen Bradley PLC’s and/or any of the following PLCs: Modicon, GE Fanuc, Siemens, Mitsubishi, Omron, Aromta, Toshiba, etc. Must have proven experience with any of the following HMI or SCADA software packages Wonderware, Rockwell, Intellution, GE Cimplicity, Ci-Tech, Iconics, Siemens, US Data, etc.
Education and/or Experience
BS in Chemical Engineering with at least 5 to 8 years of experience in process improvements, Implementation and troubleshooting is required. Experience with Six Sigma, Lean tools, FMEA, FMECA, HAZOP is required. Developing process simulation models, designing advanced application theories, evaluating process analytical technologies, and testing process simulation software. He/she also plays a lead role in providing technical guidelines in the area of job responsibility
Language Skills
Individual must be able to read, analyze, and interpret technical procedures in English, and effectively present information and respond to questions from groups of managers and clients.
Mathematical Skills
Individual must be able to apply concepts such as fractions, percentages, ratios, and proportions to practical situations.
Reasoning Ability
Individual must be able to solve practical problems, deal with a variety of concrete variables, and interpret a variety of instructions furnished in written, oral, diagram, or schedule form.
Certificates, Licenses, Registrations
Certification, licenses, and registrations will be consistent with all regulatory requirements.

Company Description:
Corning is the world leader in specialty glass and ceramics, creating and manufacturing keystone components that enable high-technology systems.

Corning’s history is filled with breakthrough technologies that have played an important role in the way the world works. We thrive on solving difficult, commercially relevant problems through an innovative and collaborative research and development process. Corning succeeds through sustained investment in R&D, more than 160 years of materials science and process engineering knowledge, and a distinctive collaborative culture.

About this company
204 reviews
Corning Incorporated is the world leader in specialty glass and ceramics. Drawing on more than 160 years of materials science and process...