TITLE: Sr. Process Engineer II
POSITION OBJECTIVE: The Sr. Process Engineer II builds upon the foundational scope of the Level 1 role with an expanded mandate encompassing advanced automation engineering, full equipment lifecycle ownership (from installation through commissioning), and direct leadership of Level 1 engineers and technical staff. This role serves as the senior technical authority across four core manufacturing processes-blown film extrusion, in-line printing, bag forming (conversion), and product packaging (cartoning)-while driving automation strategy, overseeing capital installations, and ensuring compliance with environmental, OSHA, ASI, GMP, and CTPAT standards.
QUALIFICATIONS:- Bachelor's degree in engineering (Mechanical, Electrical, Chemical, or related discipline)
- 10+ years of experience in process control or manufacturing engineering, with at least 5 years in a leadership or supervisory capacity
- Advanced knowledge of process control systems: PID control loops, PLCs, SCADA, and DCS platforms
- Hands-on experience with PLC/HMI programming (e.g., Allen-Bradley, Siemens, Beckhoff) and industrial control system design
- Demonstrated experience with robotic systems integration in a manufacturing environment
- Experience designing and deploying automated packaging systems
- Proven ability to lead equipment installation and commissioning projects from kickoff through production handoff
- Experience conducting and managing Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT)
- Familiarity with utilities and facility infrastructure requirements for new equipment (electrical, pneumatics, compressed air, water)
- Demonstrated experience managing third-party vendors and contractors on-site during installations
- Strong proficiency in LEAN manufacturing, Six Sigma, or equivalent structured improvement frameworks
- Proven capital project management experience including budget ownership, vendor selection, and schedule management
- Excellent verbal and written communication skills with the ability to present to senior leadership
- Working knowledge of general manufacturing and business principles
- Ensure consistent, dependable attendance and demonstrate a willingness to accommodate non-standard work hours as necessary.
- Capable of effectively managing job-related stress and fostering productive workplace interactions.
AUTHORITY/DECISION MAKING- Approve and implement process and automation changes that improve production efficiency, product quality, or cost-effectiveness
- Lead capital project planning and execution, including vendor selection, budget management, FAT/SAT, and project timelines
- Assign, prioritize, and oversee work across Level 1 engineers and technical staff based on business needs and project objectives
- Make final recommendations and decisions related to equipment upgrades, automation technology integration, and process control strategies
- Serve as the highest-level technical authority for root cause analysis, corrective action planning, and manufacturing-related escalations
- Approves installation plans, commissioning procedures, and equipment validation protocols
- Enforce and ensure compliance with safety, environmental, and regulatory standards across all process and automation areas
- Recommend and justify capital expenditures for automation equipment, technology, or facility infrastructure improvements
- Represent the engineering department in cross-functional meetings, project reviews, leadership presentations, and audits
JOB RESPONSIBILITIES:Leadership & Team Development- Lead, mentor, and directly supervise a team of engineers including Level 1 Sr. Process Engineers and technical professionals; conduct performance reviews and support career development
- Assign tasks, manage workloads, and build team capabilities across process engineering and automation disciplines
- Serve as escalation point and technical resource for engineering team problem-solving and decision-making
Automation Engineering- Design, develop, and implement PLC/HMI programming solutions to automate and optimize manufacturing processes across blown film, printing, conversion, and packaging operations
- Lead the integration of robotic systems into production lines, including scoping, vendor coordination, installation, programming, and operator training
- Evaluate, specify, and deploy automated packaging systems; ensure seamless integration with upstream and downstream processes
- Process data analysis
- Develop and maintain automation standards, code libraries, and documentation to support scalability and ease of maintenance
- Partner with controls and maintenance teams to troubleshoot automation systems and resolve production-impacting issues
Equipment Installation & Commissioning- Own the full lifecycle of capital equipment installations: scope development, contractor bidding, schedule management, installation oversight, commissioning, and handoff to production
- Develop and execute Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT) protocols to validate equipment performance against specifications
- Continuous improvement plans implementation
- Coordinate utilities and facility infrastructure requirements (electrical, pneumatics, compressed air, water, HVAC) for new equipment with facilities and outside contractors
- Manage on-site vendors and contractors during installation and commissioning activities; enforce safety protocols, quality standards, and schedule adherence
- Develop startup procedures, operator training materials, and equipment qualification documentation
Process Optimization & Continuous Improvement- Design and maintain documentation for process improvements that enhance yield, uptime, and product quality across all four manufacturing process areas
- Lead cost-efficiency initiatives including formulation improvements, yield optimization, and downtime reduction programs
- Partner with Technical Specialists and Level 1 engineers on ongoing improvement initiatives and active manufacturing projects
- Investigate scrap events and process deviations; implement and verify corrective actions
Capital Project Management- Develop and submit capital expenditure requests with clear business justification, ROI analysis, and technical rationale
- Manage multiple concurrent capital projects aligned with performance, budget, and schedule expectations
- Track and verify that completed projects meet expected performance targets; provide post-implementation reporting to management
Innovation & Technology Evaluation- Evaluate emerging manufacturing technologies, automation platforms, and process innovations to increase throughput, reduce cost, and improve quality
- Lead proof-of-concept trials and technology pilots; develop recommendations for broader deployment
Compliance & Safety Leadership- Actively lead Safety Committee participation; investigate incidents, implement corrective actions, and drive OSHA compliance across all process areas
- Ensure adherence to environmental standards, ASI guidelines, GMP requirements, and CTPAT security standards
- Enforce housekeeping protocols and regulatory compliance across all areas of engineering responsibility
Reporting & Collaboration- Provide clear, consistent updates on project status, automation initiatives, and process improvement progress to engineering management and senior leadership
- Work cross-functionally with Sales, Marketing, Manufacturing, Maintenance, and IT to align engineering initiatives with business objectives
- Working with Quality team on corrective actions
- Perform additional responsibilities as assigned by management
