Senior Process Engineer Chemical Manufacturing Position Overview
We are looking for an experienced Senior Process Engineer to lead process optimization, troubleshooting, and continuous improvement initiatives within a chemical manufacturing environment. This position will play a critical role in improving plant efficiency, production capacity, product quality, yield, and process safety.
The Senior Process Engineer will provide technical leadership to plant operations and collaborate with Production, Maintenance, Quality, R&D, and EHS teams to resolve complex process challenges, implement engineering improvements, and support new products, process modifications, and technology upgrades.
Key Responsibilities
- Lead process optimization and improvement initiatives to increase throughput, improve yield, reduce waste, minimize process variability, and enhance overall plant efficiency.
- Analyze manufacturing processes and operational data to identify bottlenecks, performance gaps, reliability issues, and opportunities for optimization.
- Provide senior-level technical support to plant operations and production teams, including troubleshooting complex process issues and implementing effective solutions.
- Develop, review, and maintain process documentation, including P&IDs, SOPs, Process Flow Diagrams (PFDs), operating procedures, and process parameters.
- Lead Root Cause Analysis (RCA) for process deviations, equipment failures, quality issues, and operational problems, and implement corrective and preventive actions.
- Lead continuous improvement projects using Lean, Six Sigma, and other process improvement methodologies.
- Monitor key process performance indicators and operating metrics to ensure safe, stable, reliable, and efficient plant operations.
- Develop and utilize process dashboards, reports, and data analysis tools to identify trends and support data-driven decision-making.
- Ensure manufacturing processes comply with applicable safety, environmental, regulatory, and company standards, including OSHA, EPA, and internal EHS requirements.
- Lead or participate in PSM, HAZOP, MOC, PSSR, risk assessments, and other process safety activities.
- Partner with Production, Maintenance, Quality, R&D, and EHS teams to support new product introductions, process changes, equipment modifications, and plant expansion projects.
- Evaluate and implement new technologies, process equipment, instrumentation, and automation solutions to improve plant capability, efficiency, and reliability.
- Provide technical guidance and mentorship to junior engineers and other technical team members.
- Support project planning, cost estimation, budget management, vendor coordination, and contractor activities related to process engineering projects.
- Identify opportunities to reduce operating costs, improve asset utilization, and increase manufacturing profitability.
Qualifications
- Bachelor's degree in Chemical Engineering or Mechanical Engineering with significant experience in the chemical manufacturing industry.
- 7 10 years of relevant process engineering experience in chemical manufacturing or a related industrial environment.
- Strong experience with chemical manufacturing, batch processing, continuous processing, or similar industrial operations.
- Demonstrated expertise in process optimization, troubleshooting, process improvement, and manufacturing operations.
- Strong analytical and problem-solving skills with experience using process modeling, statistical analysis, data analytics, or visualization tools.
- Strong working knowledge of Process Safety Management (PSM), HAZOP, Management of Change (MOC), Pre-Startup Safety Review (PSSR), and risk assessment methodologies.
- Proficiency in interpreting and developing P&IDs, PFDs, SOPs, process specifications, and operating procedures.
- Experience with Lean, Six Sigma, or other structured continuous improvement methodologies.
- Strong understanding of process equipment, manufacturing systems, instrumentation, and automation.
- Excellent communication, presentation, and interpersonal skills with the ability to influence and collaborate across multiple departments.
- Demonstrated ability to lead technical projects and work effectively in a fast-paced manufacturing environment.
Key Competencies
- Process Engineering & Optimization
- Technical Leadership & Engineering Judgment
- Project Leadership
- Chemical Manufacturing Operations
- Root Cause Analysis & Troubleshooting
- Lean Manufacturing & Six Sigma
- Process Safety & Risk Management
- Budget & Cost Control
- Vendor & Contractor Management
- Continuous Improvement
- Data-Driven Problem Solving
- Cross-Functional Collaboration
- Strong Safety Orientation
- Team Leadership & Mentoring
Preferred Experience
Experience in process scale-up, plant debottlenecking, automation, process control, new product introduction, equipment upgrades, or chemical process development will be highly valued.