Process Engineer-Compaction

RESPONSIBILITIES:

• Specify, source, and justify pressing equipment, tooling, feed systems, and support equipment; manage installation, commissioning, and vendor relationships
• Execute Installation, Operational, and Performance Qualification (IQ/OQ/PQ) and author the associated protocols
• Partner with Facilities and ES&H on line layout, grounding and static control, containment, and operational siting under explosives safety program
• Define and document the process: work instructions, travelers, control plans, and validated parameter windows
• Manage tooling as a program — specification, sourcing, incoming inspection, wear tracking, changeover procedures, and replacement lifecycle
• Establish in-process and final controls for dimensional, density, and integrity attributes; execute capability studies and sustain SPC
• Troubleshoot production-stopping issues including weight and density variation, feed inconsistency, sticking and picking, tooling wear, and mechanical faults
• Build and maintain the preventive maintenance program and spare parts strategy
• Drive yield, throughput, scrap reduction, and cycle time improvement against defined cost targets
• Train and qualify press operators; build sufficient bench depth so the line does not depend on any single individual
• Support first article inspection, source inspection, and customer, prime contractor, and DCMA audits
• Partner with Quality on nonconformance disposition, root cause analysis, and CAPA

Required Qualifications:

• B.S. in Chemical, Mechanical, Materials, or Industrial Engineering — or equivalent experience in a compaction-intensive manufacturing role
• 5+ years in regulated manufacturing running or supporting compression, tableting, or compaction operations (pharmaceutical, nutraceutical, powder metallurgy, ceramics, catalyst, or similar)
• Demonstrated hands-on experience with rotary or single-station presses, including setup, tooling changeover, troubleshooting, and teardown and rebuild
• Working command of powder flow, blend uniformity, granulation, and compressibility, and how each factor drives finished compact quality
• Experience authoring and executing qualification protocols and manufacturing documentation in an audited environment
• Proficiency with statistical process tools including capability analysis, DOE, SPC, and Gage R&R
• Must be a U.S. citizen or lawful permanent resident; visa sponsorship is not available
• Must be able to qualify as an employee possessor of explosive materials under ATF regulations (27 CFR Part 555)

Preferred Qualifications:

• Experience with reactive, hygroscopic, moisture-sensitive, or otherwise environmentally sensitive blends where environmental control is integral to the process
• Background in a materially accountable operation (DEA-registered, controlled substance, precious metal, or similar) where complete mass reconciliation is required
• Prior experience standing up or significantly expanding a production line, cell, or facility
• Depth in a formal quality management system — cGMP, ISO 9001, or AS9100
• Powder metallurgy or technical ceramics pressing background
• Ability to obtain and maintain a DoD security clearance