Senior Process Engineer

Senior Process Engineer

Salary: $80,000 - $125,000 per year

Location: Mcdonough, GA

Position Summary

We are seeking an experienced, hands-on Senior Process Engineer to support manufacturing operations within a plastics and packaging environment. This position focuses on process optimization, equipment troubleshooting, new product development, and continuous improvement initiatives to enhance production efficiency, quality, and cost performance.

The ideal candidate has a strong technical background in plastics manufacturing, extrusion, or injection molding, with thermoforming experience considered a plus.

This is an individual contributor role working closely with Process Technicians, Production, Maintenance, and Research & Development (R&D). Approximately 70% of the role is spent on the production floor, with the remaining 30% dedicated to engineering projects, documentation, and process analysis.

Key Responsibilities

• Provide hands-on troubleshooting and technical support for manufacturing equipment and processes.
• Identify root causes of production issues and implement effective corrective actions.
• Optimize process parameters, cycle times, equipment performance, and material utilization.
• Lead continuous improvement initiatives focused on reducing downtime, scrap, manufacturing costs, and process variability.
• Collaborate with Process Technicians, Maintenance, Production, and R&D to improve operational performance.
• Support new product launches, tooling modifications, equipment upgrades, and process development.
• Conduct process capability studies, analyze production data, and document improvements.
• Develop and maintain process documentation, standard operating procedures, and technical training materials.
• Provide technical guidance and training to manufacturing personnel.
• Support equipment changeovers, process standardization, and overall equipment effectiveness (OEE).
• Ensure compliance with established safety, quality, and manufacturing standards.

Qualifications & Experience

• Minimum 7 years of relevant manufacturing or process engineering experience preferred.
• Strong experience in plastics manufacturing, packaging, extrusion, and/or injection molding.
• Thermoforming experience is highly desirable but not required.
• Demonstrated ability to troubleshoot complex manufacturing processes and equipment in a hands-on production environment.
• Strong mechanical aptitude and understanding of manufacturing equipment and process controls.
• Experience with root cause analysis, process optimization, and continuous improvement methodologies.
• Familiarity with statistical process control (SPC), process capability analysis, DOE, or FMEA is a plus.
• Experience with ERP/MRP systems and engineering software is beneficial.
• Strong analytical, problem-solving, communication, and project management skills.
• Ability to work independently while collaborating with cross-functional teams.
• Engineering degree preferred but not required for candidates with substantial relevant technical experience.

Work Environment & Schedule

• Manufacturing environment with exposure to elevated temperatures.
• Approximately 70% hands-on production floor support and 30% engineering projects, analysis, and documentation.
• Monday–Friday schedule with flexibility to support first and second shifts, including occasional on-call needs.
• Ability to stand, walk, bend, and work around manufacturing machinery as required.