Senior Manufacturing Process Engineer

Focus: SME (Technical & Processes), cross-functional influence & alignment, large-scale project leadership, strategic influence & impact.

• Serves as SME for production processes, asset management, Lean concepts, and safety compliance & risk management.
• Independently leads large-scale, high-impact projects.
• Champions process & equipment capability studies/validation, establish & execute corrective action plans for issues, and conducts plant level PFMEA & Risk Assessments
• Shapes engineering standards and advises management on strategy.
• Provides cross-functional inter and intra departmental technical & process mentorship
• Drives innovation identification & integration
• Demonstrates thought leadership, advanced decision-making, strategic influence, and contribution to long-range strategy

Process Design and Improvement

· Lead high-impact, cross-functional projects aimed at optimizing manufacturing efficiency, product flow, and process robustness.

· Drive the development and implementation of advanced process improvements, incorporating lean, Six Sigma, and automation strategies.

· Serve as the technical authority on existing processes, identifying systemic inefficiencies and formulating sustainable solutions.

· Develop long-term process capability strategies aligned with capacity expansion, quality improvement, and business growth objectives.

· Create and maintain comprehensive documentation packages including PFMEAs, control plans, and validation protocols.

Technical Knowledge and Expertise

· Serve as the subject matter expert for assigned manufacturing processes and equipment.

· Lead troubleshooting efforts for complex manufacturing issues using structured root cause analysis methodologies.

· Develop and maintain robust process documentation including process flow diagrams, work instructions, and control plans.

· Mentor junior engineers and technicians on best practices in technical problem-solving and process optimization.

· Apply advanced engineering principles and tools (e.g., PFMEA, DOE, SPC, A3, 8D) to improve process reliability, efficiency, and safety.

· Evaluate and recommend new technologies, materials and/or equipment to improve manufacturing performance, reliability and cost.

· Support process validation, design verification, and qualification activities for equipment and new processes.

· Contribute technical input to capital projects, including layout development, equipment selection, and implementation planning.

Leadership

· Lead high-impact, cross-functional, medium and large-scale projects aimed at process innovation, improvement strategies, and strategic planning efforts, such as throughput improvements, cost reduction or defect elimination, for engineering roadmap.

· Cultivates a culture of innovation, continuous improvement, technical excellence, accountability and knowledge sharing across the Ops Engineering team.

· Communicate targeted and strategic performance data to senior management to develop long-term goals. Influence technical decision-making at the managerial level by providing expert recommendations and risk assessments.

· Align project work with long-term business objectives by translating operational goals into executable engineering initiatives.

· Balances short-term production needs with long-term strategic goals.

· Mentors and coaches all levels of engineering talent, fostering technical growth and leadership readiness within the team.

· Facilitate root cause analysis sessions, Kaizen events, and performance reviews across departments to drive sustainable improvements.

Professional Development

· Shape the long-term technical roadmap for processes and tools, and align with team development opportunities

· Actively mentor junior engineers and technicians, providing guidance, feedback, and hands-on support to accelerate their growth.

· Support the onboarding and development of new team members by sharing process knowledge, technical expertise, and company practices.

· Provide technical development leadership by introducing innovation, setting standards, and identifying and providing technical learning opportunities.

· Participate in technical training programs, certifications, and seminars to remain current on best practices, industry trends, and new technologies.

· Engage in continuous learning through professional development plans that include advanced problem-solving, project leadership, or emerging technologies.

Collaboration and Partnership

· Collaborate with suppliers to improve material quality, reduce lead times, and optimize supply chain logistics. Develop strategic partnerships with key suppliers to drive innovation, improve overall supplier performance, and enhance the resilience of the supply chain.

· Work closely with cross-functional teams, including product development, supply chain, and quality assurance, to address manufacturing challenges and achieve business objectives.

· Work cross-functionally with Production, Maintenance, Quality, EHS, and Logistics to support day-to-day operations and long-term improvement initiatives.

· Participate in multifunctional teams to investigate quality issues, equipment downtime, and process inefficiencies.

· Coordinate with external vendors, integrators, and equipment suppliers for technical specifications, commissioning, and issue resolution.

· Actively engage with CI, TPM, and Kaizen teams to drive structured problem-solving and continuous improvement culture.

Risk Management

· Collaborate with EH&S, Quality and other internal organizations to address gaps/opportunities relative to federal, state & local regulatory requirements (e.g., OSHA, NYS-DEC) and internal policies and procedures.

· Prioritize & champion compliance audits. Drive counter-measures to completion and monitor results for effectiveness.

· Own and regularly update PFMEAs, process control plans, and hazard assessments to reflect current operational risks.

· Lead complex root cause investigations and CAPA implementation for significant quality or safety incidents.

· Mentor junior engineers in understanding risk management principles, compliance obligations, and structured problem solving