Principle Process Engineer

Principal Process Engineer

Position Type: Full-Time Experience Level: 2 to 5 Years Department: Process Excellence & Engineering Location: Advanced Manufacturing Facility (Hybrid/Onsite)

About the Organization

We are a fast-growing, innovation-driven enterprise committed to manufacturing excellence, sustainability, and continuous technological advancement. Our engineering division operates at the intersection of traditional chemical/mechanical operations and cutting-edge industrial automation. As we scale our footprint and modernize our production pathways, we are seeking high-caliber talent to drive operational transformations. We offer an environment where technical ingenuity is celebrated, leadership potential is rapidly cultivated, and continuous improvement is woven into the very fabric of our operational culture.

Role Overview

The Principal Process Engineer will serve as a technical catalyst and strategic contributor within our primary manufacturing facilities. In this role, you will take ownership of identifying, analyzing, and executing high-impact process improvements designed to maximize yield, optimize throughput, enhance product quality, and minimize environmental impact.

While the designation reflects the critical technical authority of the role, we are specifically looking for an emerging, high-potential engineering professional with 2 to 5 years of hands-on industrial experience who has already demonstrated proficiency in driving structured process improvement initiatives. The successful candidate will blend foundational engineering principles with data-driven continuous improvement methodologies to challenge legacy workflows, optimize process parameters, and champion operational excellence across multidisciplinary teams.

Key Responsibilities and Accountabilities

The Principal Process Engineer carries a multifaceted mandate spanning process optimization, operational troubleshooting, cross-functional collaboration, and strategic safety compliance. Detailed responsibilities include:

1. Process Improvement and Continuous Optimization

- Lead end-to-end continuous improvement (CI) initiatives using proven methodologies such as Lean, Six Sigma (DMAIC), Kaizen, and Value Stream Mapping (VSM).

- Analyze complex production workflows to eliminate systemic bottlenecks, reduce cycle times, minimize raw material scrap, and lower overall operational expenditures.

- Design, implement, and validate process modifications, tracking outcomes against baseline Key Performance Indicators (KPIs) such as Overall Equipment Effectiveness (OEE) and First Pass Yield (FPY).

- Collaborate with operations teams to institutionalize standard operating conditions (SOCs) and standard operating procedures (SOPs) that sustain long-term operational gains.

2. Engineering Analysis, Modeling, and Data Analytics

- Conduct advanced Statistical Process Control (SPC) analyses to monitor real-time manufacturing variations, identifying deviations before they escalate into non-conformances.

- Utilize process modeling and simulation tools to forecast the impact of proposed operational shifts and system upgrades.

- Execute rigorous Root Cause Analyses (RCA) on persistent technical deviations, product quality failures, and unscheduled downtime using 5-Why, Fishbone diagrams, and FMEA frameworks.

- Design and execute Design of Experiments (DOE) to establish optimal operational windows for legacy and newly commissioned manufacturing assets.

3. Equipment, Technology, and Scale-Up Management

- Evaluate existing industrial equipment and utilities, making data-backed engineering recommendations for upgrades, retrofits, and preventative maintenance schedules.

- Partner with the Capital Projects team during the conceptual design, commissioning, qualification, and validation (FAT/SAT/IQ/OQ/PQ) of new equipment.

- Assist in seamlessly transitioning new product formulations or design prototypes from the R&D stage to stable commercial-scale mass production.

- Champion the adoption of Industry 4.0 innovations, including automated sensor integration, IoT process monitoring, and digitized reporting interfaces.

4. Cross-Functional Technical Leadership

- Act as the primary technical interface connecting Operations, Quality Assurance, Maintenance, R&D, and Environmental Health & Safety (EHS) teams.

- Mentor junior process technicians and line operators on technical standard methodologies, data literacy, and continuous improvement philosophies.

- Translate complex technological data and engineering evaluations into clear, actionable executive summaries and presentations for senior leadership.

5. Safety, Regulatory Compliance, and Quality Assurance

- Uphold the highest standards of safety compliance, actively participating in Process Hazard Analyses (PHA), Hazard and Operability studies (HAZOP), and Job Safety Analyses (JSA).

- Ensure all process modifications adhere strictly to environmental, occupational safety, and sector-specific regulatory standards (e.g., ISO 9001, ISO 14001, OSHA, cGMP).

- Drive a culture of quality where defects are systematically engineered out of the process rather than merely filtered out at quality checkpoints.

Required Qualifications and Skills

- Education: Bachelor of Science (B.S.) in Chemical Engineering, Mechanical Engineering, Industrial Engineering, Materials Science, or a related discipline. Master's degree is a plus.

- Experience: Exactly 2 to 5 years of progressive professional engineering experience within a manufacturing, chemical processing, biomanufacturing, heavy industry, or fast-paced industrial environment.

- Process Improvement Expertise: Demonstrated track record of successfully scoping, leading, and concluding measurable process improvement projects resulting in tangible yield, cost, or quality benefits.

- Methodologies: Solid working understanding of Lean Manufacturing, Six Sigma tools, and Design of Experiments (DOE). Green Belt certification is highly desirable.

- Technical Proficiencies:

Proficiency with statistical software (Minitab, JMP, or Python/R).

- Familiarity with CAD modeling software (AutoCAD, SolidWorks).

- Experience reading and creating P&IDs, PFDs, and mass/energy balances.

- Communication: Exceptional interpersonal and written communication skills, with an ability to influence cross-functional stakeholders without direct authority.

What We Offer

We provide a supportive, high-energy environment where top talent can flourish. In addition to challenging and fulfilling work, our compensation and benefits package includes:

- Highly competitive base salary with performance-driven annual bonus incentives.

- Comprehensive medical, dental, vision, and prescription insurance coverage starting on Day 1.

- 401(k) retirement savings plan with generous dollar-for-dollar employer matching.

- Robust tuition reimbursement and funding for ongoing professional certifications (Six Sigma Black Belt, PE, etc.).

- Generous Paid Time Off (PTO), dedicated volunteer days, and company-paid holidays.

- Clear, structured pathways for rapid technical leadership and management advancement.

Ready to Transform Our Industrial Processes?

If you have the technical foundation, a passion for relentless optimization, and 2 to 5 years of engineering achievements under your belt, we want to hear from you. Submit your resume, cover letter, and a brief overview of a process improvement project you spearheaded.

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