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Senior Plant Engineer

Zekelman Industries · Rochelle, IL · Full time

Posted Sep 25, 2026 · We last checked this listing on Oct 6, 2026

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Likely interview questions for this role

Written from this job description, not a generic list. Each one notes what the interviewer is really checking.

About your past

Tell me about a capital project you identified and delivered in a plant. How did you justify it?

What they are checking: Whether they can build a business case and manage a project through installation.

Tell me about a tooling or process change that improved uptime or quality.

What they are checking: Whether they've delivered measurable improvement on the production floor.

Tell me about a time operations disagreed with your engineering recommendation.

What they are checking: Whether they can listen, adjust and still push for the right answer.

How would you mentor a less experienced engineer or intern?

What they are checking: Whether they can help others grow, which a senior role expects.

What would you do

How do you make sure maintenance follows the manufacturer's procedures on critical equipment?

What they are checking: Whether they can set standards with maintenance without stepping on their authority.

How do you handle a safety concern in a project design when it adds cost and delay?

What they are checking: Whether they put safety first even when budget and schedule push the other way.

How do you manage several plant projects at once with limited resources?

What they are checking: Whether they can prioritize and keep stakeholders informed when everything feels urgent.

About the work

How do you find the bottleneck on a tube mill line, and how would you improve it?

What they are checking: Whether they understand throughput and constraints in a continuous process.

Walk me through how you'd plan a new equipment layout to improve flow.

What they are checking: Whether they consider material flow, space, safety and maintenance access together.

How do you set up quality control so improvements continue after the project ends?

What they are checking: Whether they think about sustaining controls, not just one-time fixes.

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The full job description

As published by Zekelman Industries.

You may not know our name, but you know our products. What we make is part the places where we live, work and play – all day, everyday. Zekelman is a family of companies — 100% domestic manufacturers — with a legacy dating back to 1877. We’re proud to be the largest independent steel pipe and tube manufacturer in North America and the leading innovator in multi-family housing development. We believe in what we build and what we build, builds the world around us. Hospitals, hotels, schools, bridges, airports and more. Come build a career you believe in. JOB SUMMARY Oversees manufacturing optimization, studies production methodology, manages projects, and leads continuous quality control implementation. JOB RESPONSIBILITIES • Leads and promotes healthy and safe work practices as required by regulatory agencies and Company policy • Drives production efficiencies and equipment uptime through equipment upgrades, tooling improvements, and process improvements • Analyzes and plans production workflows, equipment placement, and space utilization to improve overall manufacturing efficiency • Coordinates maintenance and repair activities to ensure all work follows manufacturer procedures and instructions, maintaining safe, efficient, and fully operational production equipment • Identifies and executes plant capital projects • Assists Operations, Maintenance and Engineering teams in evaluating lean manufacturing initiatives to strengthen safety performance, improve production flow, reduce cycle times, and drive ongoing process improvement • Analyzes equipment downtime data to identify failure trends and prioritize improvement actions • Conduct Failure Modes and Effects Analysis (FMEA) to identify potential failure points, assess risk, and drive corrective actions • Conducts root cause analysis to identify underlying failure mechanisms, validate corrective actions, and prevent recurrence of equipment, process, or quality issues • Ensures critical spares are properly identified, stocked, and readily available to support timely equipment repairs and proactive rebuilds • Provides technical guidance and mentorship on the operation and maintenance of plant equipment • Performs other duties as they might be assigned • Regular and predictable, full-time, on-site attendance during scheduled hours EDUCATION / EXPERIENCE • Bachelor's degree in Mechanical, Industrial, or Manufacturing Engineering field, or a related field • Certification in Lean, Six Sigma, or PMP preferred • 5 year industrial experience in steel industry; proven experience in managing large capital projects preferred. Experience working with vendors and/or government agencies preferred KNOWLEDGE / SKILLS / COMPETENCIES • Working knowledge of abstract and concrete variables to interpret technical instructions in mathematical or diagram form • Working knowledge mathematical concepts, such as probability and statistical inference • Working knowledge in MS Office Suite (Word, Excel, Outlook) • Strong knowledge of internal business application computer system • Basic knowledge of bar-coding management • Strong verbal and written communication skills • Strong organizational and planning skills with ability to prioritize tasks Zekelman Industries offers competitive compensation and excellent benefits, including low-cost, high-quality medical and dental benefits.  In addition, we have an amazing tuition assistance program, a bonus plan, a 401(k) plan with a generous company match, immediate vesting, and much more. M/F/D/V We are Zekelman Industries. We manufacture superior quality tubular and related products, and provide outstanding service for our valued customers. We seek to continuously advance the skills and opportunities of our employees, utilizing the latest technology and management tools available to consistently increase profitability and the enterprise value of Zekelman Industries and of our customers.

Apply at Zekelman Industries