Senior Process Engineer

Job Type: Direct Hire

We are seeking a Senior Process Engineer to establish, maintain, and optimize process engineering operations within a technical ceramics manufacturing facility. This role will own the transition of new processes from R&D to full-scale manufacturing, including equipment specification, installation oversight, commissioning, validation, and process scale-up. The position partners cross-functionally to execute engineering initiatives aligned with business-unit strategies while advancing operational excellence, safety, and continuous improvement.

Roles and Responsibilities

• Work safely and promote a strong safety culture.
• Develop ceramic powder formulations and processes for ready-to-press products.
• Lead commissioning activities, including Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), and process validation.
• Develop effective manufacturing processes for new products and materials.
• Manage capital projects from scoping and justification through equipment procurement and installation.
• Lead process improvements that increase yield or throughput.
• Lead problem-solving activities for complex process- and equipment-related issues.
• Develop, review, and update work instructions, quality-control documentation, and operator training materials as required.
• Serve as the primary interface with manufacturers and vendors supplying raw materials and process equipment, from specification through implementation, manufacturing, and acceptance testing.
• Ensure compliance with applicable safety requirements.
• Perform detailed analyses for executive review and communicate findings effectively across organizational levels.
• Monitor production standards and performance metrics, including output, downtime, scrap, and efficiency.
• Collaborate with maintenance, quality, engineering, and supply-chain teams to optimize production processes.

Education

• Bachelor’s degree in engineering or a related discipline required.
• Master’s degree preferred.

Experience

• Minimum of seven years of process engineering experience in a manufacturing environment.
• Experience in technical ceramics manufacturing preferred.
• Expertise in batching calculations, mixing, spray drying, calcining, and fine-particle milling.
• Experience with dry pressing, hot pressing, sintering, and ceramic machining processes is a strong plus.

Functional and Technical Knowledge, Skills, and Abilities

• Analytical and critical thinking: Identify root causes, implement effective solutions, improve processes, mentor others in data-driven strategies, and foster innovation through critical thinking and self-reflection.
• Business acumen: Align individual and departmental goals with organizational strategy while collaborating cross-functionally to improve operational metrics.
• Communication: Communicate technical and strategic information effectively across organizational levels while responding to feedback and stakeholder needs.
• Data analysis: Use a data-driven approach to product development, with a focus on powder production, mentor others, and communicate insights effectively to leadership.
• Project management: Independently lead multi-phase projects, including scope definition, budget management, schedule control, and contractor oversight.