Senior Process Engineer

Overview

Join Reynolds Consumer Products…and Drive Your Career across a world of opportunities! We provide amazing job opportunities for growth with competitive salaries and benefits in an exciting, dynamic, fast-paced, and high-performance organization. If you are looking to build a strong career, we have an opportunity for you! We are searching for a Senior Process Engineer to join our team located at our facility in Louisville, KY. 

Responsibilities

Your Role:

 

As a Senior Process Engineer  you will be a key contributor to a cross-functional team focused on plant reliability, process stability, and continuous improvement. This is a hands-on role requiring both technical expertise and strong collaboration skills. You will be expected to lead and support process initiatives, identify and resolve issues, and champion improvements that enhance safety, quality, and efficiency.

 

You will have the opportunity to Make Great Things Happen!

• Promote and reinforce a “safety first” culture across all process areas.
• Lead and participate in daily and weekly process team meetings to ensure alignment across operations, maintenance, and engineering.
• Champion both existing and new process development initiatives to drive improvement and operational excellence.
• Lead process optimization initiatives across separators/slitters, annealing furnaces, balers, trim systems and other processing equipment.
• Monitor and improve key process parameters to maintain product quality and equipment performance.
• Analyze and resolve process deviations, non-conformances, and product quality issues (e.g., gauge variation, flatness, surface defects, edge cracks, etc.).
• Develop and maintain process control plans for critical product families.
• Provide real-time engineering support to operators and production staff, ensuring equipment is running within specifications.
• Conduct root cause analysis (RCA) and implement corrective actions for downtime events, scrap generation, and yield loss.
• Identify and recommend process changes to reduce cycle time, energy consumption, and operational cost.
• Use data analytics tools to evaluate trends, monitor KPIs, and identify opportunities for continuous improvement.
• Provide technical guidance for the implementation of Manufacturing Execution System (MES) upgrades and data analytics platforms.
• Interface with Manufacturing Execution Systems (MES) and SCADA systems to track process conditions and historical performance.
• Work closely with Quality Assurance to ensure compliance with Food Safety standards and customer specifications.
• Support control charting, capability studies, and FMEAs to maintain and improve process reliability.
• Lead or support capital improvement projects, equipment upgrades, and process trials to introduce new technologies or products.
• Partner with maintenance and reliability teams to improve equipment uptime and reduce unplanned outages.
• Develop and train teams on Standard Operating Procedures (SOPs), PM tasks, and best practices for safe and effective operation of critical processes.
• Engage in daily Gemba walks, providing feedback and capturing operator insights for performance improvement.
• Collaborate with cross-functional teams—including union trades, engineering, and external vendors—to execute projects in accordance with plant safety and labor practices.

 

You will love it here if…

 

• You put safety first, always.
• You listen, learn, and evolve.
• You are passionate about collaboration, teamwork, and achieving shared goals.
• You treat all people with respect, operating ethically, and embrace inclusivity.
• You are committed to improving our impact on local communities.

 

Qualifications

We need you to have:

 

• Bachelor’s degree in engineering required (Mechanical, Electrical, Industrial, or related field)
• Minimum of 7+ years of progressive engineering experience in heavy industry or manufacturing environment
• Experience in aluminum flat-rolled processing or a similar industrial process preferred
• Demonstrated leadership capabilities and a desire to lead and influence cross-functional teams
• Strong proficiency in MS Office, AutoCAD, and process data analytics tools (e.g., iBA, Power BI, AVEVA, Minitab, SQL)
• Proven ability to analyze and interpret data, identify root causes, and implement effective solutions
• Solid understanding of engineering concepts, process control, and good engineering practices
• Hands-on experience with hydraulics, pneumatics an