Senior process engineer Jobs in USA

We’re working with a well-established, leading manufacturer in the CPG space that is searching for a Senior Process Engineer. This person will lead process optimization and continuous improvement initiatives at their manufacturing site on Long Island. The Senior Process Engineer leads initiatives from concept through completion, including process redesign, equipment modifications, and capital project implementation. This role operates with urgency by translating problems into clear, actionable plans and driving execution to deliver measurable results. This role will report to the Senior Director of Engineering and Maintenance. This is a newly created position and offers the opportunity to play a critical role during a pivotal growth phase for the company!

Location: Suffolk County NY

Job Responsibilities:

• Improve line throughput, reduce process variability, and increase first pass yield across operations.
• Lead process improvement initiatives to reduce downtime, increase first-pass yield, and improve labor utilization.
• Develop and maintain standard work, process documentation, and operating parameters to ensure consistent perfo
• Partner with operations teams to troubleshoot production issues and implement sustainable corrective actions.
• Use data analysis and process capability metrics to drive performance improvements.
• Ability to train, coach, and develop operators and technicians on processes, equipment, and problem-solving to ensure sustained performance improvements.
• Lead and support continuous improvement initiatives using Lean, Six Sigma, or similar methodologies.
• Identify and eliminate sources of waste across materials, labor, and machine performance.
• Facilitate root cause analysis activities (5 Why, Fishbone, Pareto analysis) to address recurring operational issues.
• Drive cross-functional improvement projects that support cost reduction.
• Support the evaluation, design, and implementation of capital equipment and process improvements.
• Provide technical input on equipment selection, process flow, and plant layout improvements
• Directly lead commissioning and validation activities for new equipment and processes.
• Ensure new processes are scalable, efficient, and aligned with operational standards.
• Collaborate with maintenance and engineering teams to improve equipment reliability and performance
• Troubleshoot and improve mechanical systems and electrical/control systems.
• Lead or support equipment modifications, retrofits, and installations.
• Partner with Quality and Operations to improve process capability and reduce defects.
• Support investigations related to process deviations, non-conformances, and product quality issues.
• Assist in implementing corrective and preventive actions (CAPAs) tied to process performance.
• Serve as a technical liaison between Operations, Quality, Maintenance, and Supply Chain.
• Partner with production leadership to implement process improvements on the shop floor.
• Support training and coaching of production teams on process changes and best practices.

Required Skills/Qualifications:

• Bachelor’s degree in a related field preferred.
• 5–7+ years of experience in process engineering within manufacturing environments such as personal care, pharmaceuticals, food, consumer products, or adjacent industries.
• Experience working in high-volume manufacturing environments
• Demonstrated success improving operational performance through process improvement initiatives.
• Experience leading capital projects, equipment implementation, or process design improvements.
• Strong analytical and data interpretation skills.
• Experience with Lean Manufacturing, Six Sigma, or continuous improvement methodologies
• Ability to perform root cause analysis and implement sustainable corrective actions.
• Ability to manage cross-functional projects from concept through implementation.
• Demonstrate strong initiative by proactively identifying opportunities, taking ownership, and leading improvements without the need for direction.
• Comfortable working on the manufacturing floor and engaging directly with operators and supervisors
• Strong collaborator who works effectively across operations, engineering, and quality teams.