Process Engineer Sr.

About the role

• Safety is the most important part of all jobs within the hiring organization. Candidates must be able to demonstrate the ability to initiate, lead, and uphold safety policies, practices, procedures, and housekeeping standards. The Process Engineer Sr. reports to the VP of Engineering and is responsible for developing, optimizing, and sustaining manufacturing processes to ensure safe, stable, and efficient operations. This role will support startup, commissioning, and production readiness activities, and will evolve over time from initial process establishment and validation to ongoing process control, capability improvement, and troubleshooting. This position requires excellent technical aptitude, organization, and communication skills. 

What you'll do

• Develops and optimizes manufacturing processes to ensure safety, quality, delivery, and cost targets (SQDC) are achieved, in that priority order.

• Supports production through shop floor engagement, understanding production goals and contributing where possible to assist. 

• Defines process parameters, standard operating conditions, and quality control methods for new and existing processes.

• Supports equipment commissioning, capability studies, and process validation during startup activities.

• Conducts process risk assessments and implements controls to ensure safe and reliable operation.

• Creates and maintains process documentation including work instructions, PFMEAs, control plans, process flow diagrams, and standard operating procedures.

• Analyzes production data to identify trends, improve process capability, and drive root-cause investigations.

• Collaborates cross-functionally with operations, maintenance, quality, and engineering to resolve process issues and support continuous improvement.

• Leads trials, experiments, and test plans to evaluate new materials, methods, and technologies.

• Drives productivity initiatives to increase throughput, yield, and equipment utilization while reducing scrap and cost.

• Supports capital projects from a process perspective, including defining functional requirements and acceptance criteria.

• Provides process engineering support to maintenance and operations; responds to process deviations and equipment performance concerns.

• Performs other assignments as directed by the leadership team.

Required Qualifications

• B.S. in Engineering (Materials, Metallurgical, Mechanical, Chemical, or related discipline) from an ABET-accredited program required. 

• Excellent verbal and written communication skills with all levels of personnel within the company and with equipment suppliers.

• Proficiency with Microsoft Word, Excel, PowerPoint, Project, and CAD tools.

• Ability to self-start and work autonomously in a highly dynamic startup environment.

• Demonstrated ability to organize, prioritize, and manage multiple tasks and process improvement activities.

• Experience leading or participating in lean manufacturing and continuous improvement initiatives.

• Ability to analyze complex data sets, troubleshoot process issues, and implement corrective actions.

Preferred Qualifications

• Experience in an industrial or manufacturing environment with hands-on process engineering responsibilities.

• Desire to grow into an engineering leader for the organization. 

• Exposure to automation systems including robotics, AMRs, and integrated manufacturing cells is a plus.

• Experience with 2D/3D modeling tools and process simulation software.

• Experience with MES, SCADA, CMMS, SAP, Power BI, or similar digital manufacturing systems.

• Background supporting highly regulated production environments (Aerospace, Medical, or similar industries).

• Familiarity with formal quality tools including Pareto, 5-Why, 8D, Ishikawa, and A3.

• Experience operating in an AS9100 governed environment preferred

Physical Requirements

• Stand/walk for extended periods; lift/push/pull up to 50 lbs; climb stairs and ladders.

• Work near high‑temperature equipment, molten metal, and rotating machinery; exposure to noise and fine particulate (with controls).

• Ability to work in noisy, hot, or potentially hazardous environments (with appropriate PPE).

• Comfortable working with heavy machinery and tools.

• Wear required PPE: safety shoes, eye/face protection, gloves, FR garments, hearing protection, and respirators as applicable.