Job Title: Lead Process Engineer
Department: Operations
Location: Tavernerio (CO)
Reports to: Plant Manager
Purpose of Job: The Lead Process Engineer, which is a key managerial and technical leadership role within the plant, is responsible for ensuring the operational continuity, technical robustness and continuous development of the plant, overseeing both Process Engineering and Production activities.
The role combines process engineering expertise, production leadership and people management, acting as the main reference point for operational performance, process optimization and manufacturing excellence.
The Lead Process Engineer directly manages the Process Engineering and Production teams, ensuring alignment between technical standards, production targets and workforce development.
The position works in close collaboration with Maintenance, Quality, Supply Chain and Plant Management to guarantee efficiency, waste reduction, safety, operational stability and continuous improvement across the entire manufacturing operation.
Key Activities / Measurables
Safety
• Promote a strong “safety culture” across all involved operational areas.
• Ensure compliance with applicable legal regulations and Company policies regarding occupational Health and Safety.
• Integrate safety principles into process changes and technical improvements.
Activities
Process Engineering & Continuous Improvement
• Optimize converting processes to improve productivity, yield, machine reliability and scrap reduction through data-driven analysis and continuous monitoring.
• Define, standardize and continuously improve critical process parameters to ensure process stability, repeatability and operational capability.
• Analyze cycle times, setups and production losses, implementing SMED and engineering solutions to maximize line utilization and operational efficiency.
• Drive structured root cause analysis on recurring process and equipment issues in collaboration with Maintenance, ensuring sustainable corrective actions.
• Support Quality and Production in the industrialization and stabilization of new products, customer requirements and process changes.
• Lead continuous improvement initiatives leveraging Lean Manufacturing, problem solving methodologies and performance analysis.
• Strengthen technical competencies across the organization through coaching, process standardization, knowledge sharing and structured development plans.
• Ensure accurate and updated technical documentation, including operating standards, process flows, machine parameters and control plans.
• Actively contribute to the relevant SPS (Sonoco Performance System) pillars, promoting operational excellence and performance culture.
Production
• Ensure safe, stable and efficient production execution across shifts, guaranteeing continuity, quality compliance and achievement of operational targets.
• Coordinate Production Supervisors and shopfloor teams, optimizing manpower allocation, workflow organization and operational discipline.
• Monitor and analyze key production KPIs (output, efficiency, downtime, scrap, labor utilization), driving timely corrective and preventive actions.
• Identify operational deviations and performance trends through production and quality data analysis, ensuring rapid issue resolution and continuous improvement.
• Ensure full compliance with safety standards, operating procedures, quality requirements and company policies across all production activities.
• Support escalation management and troubleshooting activities in coordination with Maintenance, Quality and support functions to minimize operational impact.
• Promote a proactive safety culture, ensuring safe execution of production, setup and maintenance activities.
• Ensure effective communication, reporting and structured shift handovers to guarantee operational alignment and business continuity.
• Support people development through coaching, training coordination and competency growth of supervisors and operators.
• Actively contribute to the relevant SPS (Sonoco Performance System) pillars and operational excellence initiatives.
Cross-Functional Collaboration
• Collaborate daily with Production, Maintenance, Quality and Supply Chain teams to monitor plant performance, address operational constraints and improve process reliability.
• Provide direct technical support on the shopfloor to rapidly manage process deviations, quality issues and operational inefficiencies.
• Partner with Commercial, Quality and Supply Chain functions to evaluate technical feasibility, process capability and customer-specific requirements.
• Support the standardization and capability development of operators and supervisors through technical guidance, training and best practice sharing.
• Foster a collaborative, data-driven and solution-oriented approach across functions to support operational performance and continuous improvement.
Requirements
• Degree in Engineering (Industrial, Mechanical, Materials, Chemical Engineering or equivalent).
• Proven experience in process engineering, quality management or continuous improvement roles within manufacturing environments.
• Preferably experience in paper, paper converting or other continuous-process industries with high technical variability.
• Hands-on experience in managing non-conformities, customer complaints and supplier quality issues.
• Strong ability to analyze production and quality data and translate them into corrective and preventive actions.
• Practical experience working closely with production teams in a multi-shift manufacturing environment.
• Structured, pragmatic and data-driven problem-solving approach.
• Clear communication skills with both technical and operational teams.
• Strong sense of ownership, reliability and attention to detail.
Work Location
Tavernerio (CO). Availability to travel may be required.
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We are an equal opportunity employer, and we strictly prohibit and do not tolerate discrimination against employees, applicants or any other covered persons because of race, color, religion, national origin or ancestry, sex, pregnancy, sexual orientation, marital status, gender identity or expression, age, disability, genetic information, veteran status, or any legally protected characteristic.