Process Engineer (Melrose Park)

Position Summary

The Process Engineer is responsible for analyzing, developing, and optimizing manufacturing processes to improve efficiency, quality, safety, and productivity throughout Avlon's manufacturing operations. This role leads continuous improvement initiatives, evaluates production processes, reduces waste, and supports implementation of best manufacturing practices. The ideal candidate possesses a Bachelor's degree in Process Engineering or Chemical Engineering, experience in a regulated manufacturing environment, and a strong background in Lean Manufacturing and Kaizen methodologies.

Essential Responsibilities

· Analyze, improve, and optimize manufacturing processes to increase productivity, efficiency, and product quality.

· Identify process bottlenecks and implement effective engineering and design solutions for line optimization, changeover reduction, automation, CAPEX, and filler validation.

· Develop and maintain manufacturing procedures and standard operating procedures (SOPs).

· Lead Kaizen events and continuous improvement initiatives.

· Apply Lean Six Sigma methodologies to reduce waste, improve process capability, and increase operational efficiency.

· Conduct root cause analyses and implement corrective and preventive actions (CAPA).

· Monitor key performance indicators (KPIs) and recommend data-driven improvements.

· Collaborate with Production, Quality, Maintenance, R&D, Warehouse, and Supply Chain teams.

· Support equipment selection, installation, validation, and process qualification.

· Ensure compliance with GMP/cGMP standards and company quality requirements.

· Perform time studies, workflow analyses, and labor utilization studies.

· Prepare technical reports and present recommendations to management.

Required Qualifications

· Bachelor's degree in Process Engineering or Chemical Engineering (required).

· Minimum 3 years of process engineering experience in a manufacturing environment (5 years preferred).

· Strongly preferred: Cosmetics manufacturing experience.

· Acceptable alternatives: Food or Pharmaceutical manufacturing experience.

· Experience working in regulated manufacturing environments.

Required Skills

· Lean Manufacturing (Required)

· Kaizen (Required)

· Lean Six Sigma (Required)

· Process Mapping and Workflow Optimization

· Root Cause Analysis and Corrective Actions

· Statistical Process Control (SPC)

· Excellent analytical, problem-solving, and project management skills

· Strong written and verbal communication skills

Preferred Qualifications

· Lean Six Sigma Green Belt or Black Belt Certification

· Experience with ERP systems (Sage X3 preferred)

· Experience with compounding and filling operations

· Experience with GMP/cGMP manufacturing

Compensation

· Salary Range: $90,000-$110,000 (commensurate with education, skills, and experience)

. Annual Performance Bonus

Avlon is not currently sponsoring or offering relocations for this position