Senior Process Engineer

Job Title: Senior Process Engineer

Location: Knoxville, TN 37932



Work Arrangement: On Site



Experience Level: Mid-Senior



Experience Required: 7 Years



Education Level: Bachelor's Degree



Job Function: Manufacturing



Industry: Mechanical or Industrial Engineering



Compensation: $120,000/Year


Job Overview

We are seeking a Senior Process Engineer to establish, maintain, optimize, and scale process engineering operations within a technical ceramic manufacturing facility.

This position will serve as the primary owner for transitioning new processes from R&D into full-scale manufacturing , including equipment specification, equipment installation oversight, commissioning, validation, and process scale-up activities.

The Senior Process Engineer will work cross-functionally with manufacturing, maintenance, quality, engineering, and supply chain teams to execute engineering initiatives aligned with business objectives while driving operational excellence, safety, process optimization, yield improvement, throughput gains, and continuous improvement .

Must-Have Skills

• Strong track record of developing, optimizing, troubleshooting, and scaling manufacturing processes .

• Experience managing vendors, contractors, FAT/SAT testing, and capital projects from concept through implementation .

• Strong expertise in root cause analysis and data-driven problem solving for complex manufacturing and equipment issues.

• Minimum 7 years of process engineering experience in a manufacturing environment .

• Strong experience with process validation, process control, process optimization, and manufacturing process development .

• Demonstrated ability to lead commissioning, equipment installation, process scale-up, and validation activities .

• Strong project management skills, including scope definition, budgeting, scheduling, procurement, installation, and contractor oversight.

Key Responsibilities

• Work safely and actively promote a strong safety mindset throughout manufacturing operations.

• Develop ceramic powder formulations and process development methods to produce ready-to-press products.

• Lead commissioning activities, including Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), and process validation .

• Develop the best-method manufacturing processes for new products and materials.

• Manage capital projects from initial scoping and justification through equipment procurement, installation, commissioning, and implementation.

• Identify and implement process improvements that deliver yield and throughput gains .

• 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 development through implementation, manufacturing, and acceptance testing.

• Ensure compliance with all applicable safety requirements.

• Perform detailed data analysis for executive review and effectively communicate findings across all 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 manufacturing processes.

Education

• Bachelor's degree in Engineering or a related discipline required.

• Master's degree is a plus.

Required Experience

• Minimum 7 years of experience in a process engineering role within a manufacturing environment .

• Preferred experience in a technical ceramic manufacturing environment .

• Particular expertise in:

  • Batching calculations

  • Mixing

  • Spray-drying

  • Calcining

  • Fine particle milling

• Additional experience in the following areas is considered a strong plus:

  • Dry-pressing

  • Hot-pressing

  • Sintering

  • Ceramic machining processes

Functional / Technical Knowledge, Skills & Abilities Analytical & Critical Thinking

Ability to 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

Ability to align individual and departmental goals with organizational strategy while collaborating cross-functionally to improve operational metrics.

Communication

Ability to effectively communicate technical and strategic information across all levels of the organization while remaining responsive to feedback and stakeholder needs.

Data Analysis

Utilize a data-driven approach to product development, with a key focus on the powder production aspect. Ability to mentor others and effectively communicate analytical insights to leadership.

Project Management

Ability to independently lead multi-phase projects, including scope definition, budget management, schedule control, vendor management, procurement, equipment installation, commissioning, and contractor oversight .

Nice-to-Have

• Experience in technical ceramics manufacturing is highly preferred.

• Experience with ceramic powder processing and advanced ceramic manufacturing processes.

• Experience with dry-pressing, hot-pressing, sintering, and ceramic machining.