Knauf Australia · 13 hours ago
Process Engineer
Conroe, TX
Full-time
Onsite
Mid LevelKnauf Australia is a leading manufacturer of modern insulation materials and gypsum wallboard systems. The Manufacturing Process Engineer will optimize plasterboard production processes, driving improvements in safety, quality, throughput, and cost on the plant floor.
Building MaterialConstructionManufacturing
No H1B
Responsibilities
Lead process optimization across plasterboard unit operations: calcination, mixing, forming line, drying, cutting, edge finishing, stacking, and packaging
Improve OEE, reduce scrap, and shorten cycle times through data-driven problem solving and continuous improvement
Develop and maintain PFMEA, control plans, standardized work, and work instructions for stable, repeatable processes
Apply Lean/Six Sigma tools (DMAIC, 5S, Kaizen, SPC, DOE) to address root causes and lock in gains
Partner cross-functionally with Production, Quality, Maintenance, Supply Chain, and R&D on NPI, product variants (e.g., fire-rated, moisture-resistant), and scale-up
Drive automation and mistake-proofing; collaborate on controls/PLC improvements, recipe management, and real-time process monitoring
Plan and execute trials and validations; establish IQ/OQ/PQ and capability analyses where applicable
Build dashboards, monitor process health, and lead daily/weekly performance reviews
Champion a safety-first culture and ensure compliance with relevant standards (e.g., ISO 9001) and site procedures
Mentor technicians/engineers and contribute to our continuous improvement culture
Qualification
Required
Located in or near Camellia
Experience with PFMEA, control plans, standardised work and process validation (including IQ/OQ/PQ and capability studies)
Proficiency in statistical analysis (SPC, DOE), problem solving and data tools (Excel, Power Bi, Minitab)
Experience in continuous process industries or building materials; Plasterboard/gypsum is highly regarded
Proven use of Lean/Six Sigma methodologies (Green/Black belt) is an advantage
Ability to work from the Camellia Manufacturing site full time – This is not a Work from Home Role
Full and Unrestricted Australian working rights – We do not offer visa sponsorship
Valid Police Check
Bachelor's or master's in engineering (Mechanical, Chemical, Industrial, Materials, Electrical) or a closely related Science discipline
Successful completion of pre-employment medical
Benefits
Competitive base salary + super
Phone & Laptop provided
14 weeks Parental Leave (primary carer)
Yearly Pay Review
Access to discounts on Health Insurance, Gym Memberships, Qantas lounge, Novated leasing and trade discounts
Leadership pathway: structured development, mentorship, and opportunities to lead visible, cross-functional initiatives
Free onsite parking
Free onsite Physio
Company
Knauf Australia
Knauf is a manufacturer of insulation materials, drylining systems, plasters, and accessories.
501-1,000 employees
Funding
Current Stage
Late StageCompany data provided by crunchbase