Position Summary

The Senior Process Engineer is responsible for designing, improving, and optimizing manufacturing processes to ensure safety, quality, efficiency, and cost-effectiveness. This role leads process improvement initiatives, supports production operations, troubleshoots manufacturing issues, and drives continuous improvement programs across the facility.

Key Responsibilities

• Analyze and optimize manufacturing processes to improve productivity, quality, and profitability.
• Lead continuous improvement projects using Lean Manufacturing, Six Sigma, and other operational excellence methodologies.
• Develop, document, and maintain process flow diagrams, work instructions, SOPs, and process specifications.
• Investigate production issues, identify root causes, and implement corrective and preventive actions (CAPA).
• Monitor key process performance indicators (KPIs) and recommend improvements.
• Collaborate with Production, Quality, Maintenance, Supply Chain, and R&D teams to support manufacturing objectives.
• Lead process validation, qualification, and scale-up activities for new products and processes.
• Evaluate equipment performance and recommend upgrades, modifications, or automation opportunities.
• Support safety initiatives and ensure compliance with OSHA, environmental, and company requirements.
• Conduct risk assessments, FMEA studies, and process capability analyses.
• Manage capital improvement projects from concept through implementation.
• Provide technical guidance and mentorship to junior engineers and production personnel.
• Support audits and regulatory inspections as needed.

Qualifications

Education

• Bachelor's degree in Chemical Engineering, Industrial Engineering, Mechanical Engineering, Manufacturing Engineering, or related field.
• Master's degree preferred.

Experience

• 7+ years of manufacturing or process engineering experience.
• Experience in consumer products, chemicals, pharmaceuticals, food manufacturing, or related industries preferred.
• Proven experience leading process improvement and capital projects.

Required Skills

• Strong knowledge of process engineering principles and manufacturing operations.
• Experience with Lean Manufacturing, Six Sigma, Kaizen, and Root Cause Analysis.
• Knowledge of statistical analysis and process control techniques.
• Ability to read and develop PFDs, P&IDs, and engineering drawings.
• Strong project management and organizational skills.
• Excellent analytical and problem-solving abilities.
• Strong communication and leadership skills.
• Proficiency in Microsoft Office and ERP systems (such as SAP).

Preferred Certifications

• Lean Six Sigma Green Belt or Black Belt
• PMP (Project Management Professional)
• Professional Engineer (PE) license (where applicable)

Typical Performance Metrics

• OEE (Overall Equipment Effectiveness)
• Production throughput
• Yield improvement
• Scrap reduction
• Cost savings
• Downtime reduction
• Safety performance
• CAPA closure effectiveness
• Process capability (Cp/Cpk)

Physical Requirements

• Ability to work in manufacturing and warehouse environments.
• Ability to stand, walk, climb stairs, and occasionally lift up to 25 pounds.
• Occasional travel may be required.

Pay: $75,000.00 - $85,000.00 per year

Benefits:

• 401(k) matching
• Dental insurance
• Health insurance
• Paid time off
• Vision insurance

Work Location: In person