Glass, Furnace and Melting Engineer Lead
Location: Granville, Ohio – United States
Sr. Engineering Lead
PURPOSE OF THE JOB
The primary responsibility of the Stable Operations (SO) Glass, Furnace and Melting Engineer is to be a Subject Matter Expert (SME), providing global support to OC CSB reinforcement business and plants. The goal is to achieve manufacturing excellence and industry cost leadership by improving performance, reducing process variability and preventing or mitigating upsets. A Stable Operations Glass, Furnace and Melting Engineer is accountable to build competence and capacity in the organization to improve business outcomes by working directly with plant furnace engineers and technical leaders during major support activities, process reviews and training.
Support activities involve leading or supporting furnace heat-ups, life extension programs, repairs, glass conversions, throughput changes, glass drains, troubleshooting and helping identify, develop, implement and support new technologies for the melting of glass and its delivery to forming.
The Glass, Furnace and Melting engineer must be able to review and interpret data from multiple sources and systems and be a SME in melter systems and standard practices to provide technical guidance to OC leadership, plant leaders, and plant batch and melting engineers to improve operations performance in terms of safety, productivity, throughput, energy and life.
Reports to: Stable Operations Leader, Granville
Span of Control: 0 direct reports, provides technical direction to junior SO Furnace Engineers, CSB plant Furnace Engineers and Furnace Development Program engineers in training.
Furnace and Melting Operations Plant Technical Support (40 to 60%)
- SME and mentor the OC CSB plant furnace engineers at supported plants and globally by establishing close working relationships through phone contact, network meetings and visits
- Continuously identify, develop and share Standard Instructions and Best Practices, Lessons Learned and cost reduction opportunities with plants
- Collaborate with SO Batch Engineers and plants making batch adjustments or investigating new raw materials, with responsibility to approve SO Batch Engineer prepared batch formulations prior to implementation by plants
- Conduct and lead audits and surveys to identify gaps andprioritize CE/NE improvement opportunities
- Infrastructure – assessment of furnace and front end condition to identify areas of concern or repair and opportunities for life extension using specialize equipment, i.e. endoscope, ultrasonic
- Operational – hands on review of operating conditions like combustion air-fuel ratios and profiles, use of CPVs and experience to identify key opportunities to improve efficiencies, throughput, quality and energy usage
- Process Reviews – comparison to standards and best practices, discussion of escalations for coaching, report prioritized recommendations for improvement and mitigating operating risks
- Recommend and direct coordinated actions to improve furnace performance (life, throughput, cost or technology) and operating practices
- Define furnace skill requirements, training (class and hands on) and capability assessments for global, region and plant resources
- Lead or collaborate on cross functional technical teams working on upset response containment, troubleshooting and focused improvement activities
- Review reported performance data and Root Cause Analyses for Escalations and Near Misses for network learning to prevent future escalations and minimize risk
Furnace and Melting Operations Capital Project, Major Repair and Technology Support (60 to 40%)
- Partner with Capital Delivery, Capital Sourcing, plants, engineering companies and equipment suppliers to ensure the best balance between capital expenditure and operational efficiency for product and asset life cost including process layouts, concept design, specification and technology/equipment selection
- Facilitate preliminary safety, risk and failure analysis and installed evaluation of new technology, refractory trials, design or operating changes and controls
- Provide scope of work and required planning and oversight for major repairs including crown overcoats, skimmer and refractory repairs, water jackets, electrode pushes, and zone recabling, drains and heat ups
- Lead safe vertical start-up of melter from commission to plant operation for new, rebuilt or repaired furnaces and associated infrastructure including melter and front end systems such as combustion skid and burners, pressures and temperatures, electrical boost and electrical, wind and water cooling, controls, emergency backup and refractory.
- Develop heat up plans and personnel and contractor requirements
- Conduct pre-light checklist reviews for build and commissioning
- Make furnace light off readiness recommendation
- Manage heat up activities including heat up rate and expansion
- Coordinate glass delivery to forming operations and tune front end settings
- Establish baseline conditions for plant operation for critical process parameters
- B.S. in engineering or technical field, like mechanical engineering, ceramic engineering, glass science, materials science, etc.
- The candidate should have minimum of 4 years manufacturing experience in the glass, refractory or ceramic industry, with direct exposure to the high temperature melting process and associated furnace systems.
KNOWLEDGE, SKILLS & ABILITIES:
- Experience working with multiple plants and melter systems in a support role
- Familiarity with melting operations, capital projects, melter hot repair, gas-oxy and gas-air combustion, electrical boosting, refractory, batch house operations, glass and glass raw materials is desired.
- Capable of clearly communicating technical concepts and results
- Comfortable sharing (written and verbal ) with all levels of operations from operators to plant leaders to vice presidents to explain and demonstrate the benefits and risks of any action plant, program or project
- Use influence and diplomacy to achieve the best results for the business by collaboration and teamwork
- Deliver prompt accurate results independently or as part of a team which demonstrates input, organizational abilities and technical skills across the organization
- Motivate others who are not direct reports to accomplish tasks and improve operations
- Proficient in the definition and solution of complex technical problems
- Frequent travel is inherent in this position. At times, the candidate will be expected to travel without notice to support Manufacturing during emergency conditions.
- Interest to recognize, identify and apply new technical knowledge in areas of specialization, with ability to go outside immediate environment to seek direction, input new ideas, engineering resources, equipment, etc.
- General computer skills (ex. Microsoft Word, Excel, PowerPoint, and Outlook), familiarity with databases and control systems, excellent mathematical and analytical skills
- Training and experience in CI, TPM or Six Sigma is desired
- Ability to speak a second language such as Spanish, French, Chinese or Russian desired
- Experience in high temperature refractory materials used in glass furnace designs.
- Required Licenses and/or Certifications: None
About Owens Corning
Owens Corning (NYSE: OC) develops, manufactures and markets insulation, roofing, and fiberglass composites. Global in scope and human in scale, the company’s market-leading businesses use their deep expertise in materials, manufacturing and building science to develop products and systems that save energy and improve comfort in commercial and residential buildings. Through its glass reinforcements business, the company makes thousands of products lighter, stronger and more durable. Ultimately, Owens Corning people and products make the world a better place. Based in Toledo, Ohio, Owens Corning posted 2015 sales of $5.4 billion and employs about 15,000 people in 25 countries. It has been a Fortune 500® company for 61 consecutive years. For more information, please visit www.owenscorning.com.
A career at Owens Corning offers the ability to enhance your expertise and achieve your personal and professional aspirations. Through it all, we’ll empower you with an environment that encourages open communication and big ideas, competitive pay for your performance, comprehensive benefits, and more opportunities to make your impact.
Must be eligible to work in the U.S. on a permanent basis.
Owens Corning is an Equal Opportunity, Affirmative Action employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, protected veteran status or status as an individual with a disability.
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