Our client is seeking - Senior Process Engineer, responsible for establishing, maintaining and optimizing process engineering operations within a technical ceramic manufacturing facility. This role serves as the primary owner for transitioning new processes from R&D into full-scale manufacturing, including specifying equipment, oversight of equipment installation, commissioning, validation, and process scale-up activities. The position partners cross-functionally to execute engineering initiatives aligned with business unit strategies, while driving operational excellence, safety, and continuous improvement.
Roles & Responsibilities: including but not limited to
Work safely and encourage a safety mindset
Ceramic powder formulation and process development to produce ready-to-press products
Lead commissioning activities, including Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), and process validation.
Develop best method manufacturing processes for new products and materials
Manage capital projects from scoping and justification, through equipment procurement and installation.
Responsible for process improvements that deliver yield or 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 as required.
Serve as the primary interface with manufacturers and vendors that supply raw materials and process equipment to the company, from specification setting through implementation, into manufacturing and acceptance testing.
Ensure compliance with safety requirements
Perform detailed 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 production processes.
Education:
Bachelor's degree in Engineering or related discipline. Master's degree a plus
Experience:
Minimum 7 years in a process engineering role in a manufacturing environment.
Preferred experience in a technical ceramic manufacturing environment
Particular expertise in batching calculations, mixing, spray-drying, calcining, and fine particle milling.
Additional experience in dry-pressing, hot-pressing, sintering, and ceramic machining processes considered a strong plus.
Functional/Technical Knowledge, Skills & Abilities:
Analytical/Critical Thinking - 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 - Align individual and/or departmental goals with organizational strategy, while collaborating cross-functionally to improve operational metrics.
Communication – 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, while mentoring others and effectively communicating insights to leadership.
Project Management - Independently lead multi-phase projects, including scope definition, budget management, schedule control, and contractor oversight.
Senior Process Engineer • Knoxville, TN, USA
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