Lead Process Engineer – Process Line Start-Up (Aluminium Can Manufacturing)

Ball, a global leader in sustainable aluminium packaging, is driving meaningful transformation—join us in shaping a future where aluminium makes a difference.

About the Role

Ball is proud to have been named to Newsweek’s 2023 Top 100 Global Most Loved Workplaces. Our global team champions sustainable packaging solutions, from infinitely recyclable aluminium cans and cups to aerosol bottles, fostering a cleaner planet through innovation.

As a Process Line Start-Up Professional, you’ll partner with Ball’s Process Engineering team to deliver New Build, New Line, and Line Conversion start-ups in spray and necker areas. Your core responsibilities will centre on process efficiency, equipment performance, and error reduction, prioritising safety while also advancing operational metrics such as resource efficiency and environmental compliance.

Primary Purpose

You will lead a dedicated process area based on your expertise, providing technical oversight to ensure:

• On-time and efficient start-up of new releases and conversions
• Adherence to safety, efficiency, and sustainability standards
• Quality assurance throughout operational phases
• Deep technical expertise and knowledge transfer across teams

Essential Responsibilities

Core Accountabilities

• Champion safety. Uphold a zero-tolerance safety culture—train team members, enforce compliance, and integrate risk mitigation into all operational processes.
• Mainstage line launches. Oversee start-up, commissioning, and ramp-up, ensuring equipment meets design specifications with hands-on technical guidance during installation and initial production stages.
• Process Subject-Matter-Expert (SME). Apply advanced process knowledge to troubleshoot and stabilise line performance by addressing mechanical, chemical, and procedural issues in real time.
• Sustainable training delivery. Spend 80% of training on-the-job (OJT)—including practical setup, diagnoses, and maintenance—and 20% in classroom sessions, cultivating skills in your specialised branch.
• End-to-end problem-solving. Conduct structured root cause analyses to resolve persistent recurring issues, and establish robust corrective actions to enhance long-term line reliability.
• Document excellence. Validate Standard Operating Procedures (SOPs), work instructions, and training materials to reflect state-of-the-art compliance and operational best practises.
• Compliance in action. Ensure food safety, sanitation, and housekeeping align with regulatory standards throughout all start-up activities and equipment transitions.
• Parts and resource lead. Track and verify availability of materials, tooling, and critical start-up resources—proactively addressing gaps to avoid operational disruptions.
• Collaborate with teams. Work closely with Engineering, Production, and Quality to smoothly transition new lines from the start-up phase into steady-state production.
• Disseminate best practises. Record lessons learned from each project to benefit future build projects, advancing continuous improvement across the organisation.
• Drive KPI performance. Achieve targets for efficiency and scrappage reduction in all new builds, conversions, and line introductions, adhering to approved ramp-up schedules.
• Tech transfer & upskilling. Mentor recruits and plant personnel, especially during critical escalations, to champion process awareness, self-reliance, and long-term capability building.
• Emergency responsiveness. Provide breakdown support during start-up measures to mitigate downtime and restore operations quickly.
• Support line conversions. Facilitate size or specification changes, ensuring teams execute safe, efficient, and repeatable adaptions.
• Align with global standards. Leverage Ball Operations Excellence (BOE) frameworks to elevate performance across all dimensions of industry-relevant best practices.