Job Title: Senior Process Engineer
Functional Reporting: Manager - Process Engineering
Department: Process Engineering
SummaryThe Senior Process Engineer provides technical leadership for the development, scale-up, optimization, and continuous improvement of manufacturing and assembly processes for new and existing cosmetic products. This role serves as a subject matter expert for process design, technology transfer, equipment evaluation, and operational excellence initiatives. The Senior Process Engineer leads complex projects, mentors junior engineers, and collaborates cross-functionally to ensure safe, efficient, GMP-compliant, and cost-effective manufacturing operations while supporting business growth and innovation.
Essential Duties and Responsibilities- Lead technical evaluation of new product opportunities, customer requirements, and manufacturing feasibility assessments, including equipment capability, capacity analysis, process risk identification, and commercialization strategy.
- Serve as the primary technical lead for new product introductions, ensuring successful implementation from development through commercial production.
- Lead customer technical transfers, process validations, and scale-up activities, ensuring alignment between customer specifications and manufacturing capabilities.
- Evaluate manufacturing processes and identify opportunities for process optimization, automation, productivity improvements, and cost reduction.
- Partner with Process Engineering Manager and Engineering leadership to define capital expenditure (CAPEX) requirements, justify investments, and support equipment selection, installation, commissioning, and qualification activities.
- Design, execute, and oversee pilot batches, process trials, and validation studies; analyze results and prepare technical reports with recommendations for implementation.
- Provide technical leadership during process troubleshooting activities, utilizing root cause analysis and data-driven methodologies to resolve complex manufacturing challenges.
- Lead continuous improvement initiatives focused on yield enhancement, waste reduction, cycle time improvement, labor efficiency, equipment reliability, and overall operational effectiveness.
- Collaborate with Quality, Production, R&D, Supply Chain, and Engineering teams to ensure robust manufacturing processes and successful project execution.
- Develop, review, and approve manufacturing, filling, and assembly specifications, procedures, and process documentation in compliance with cosmetic GMP requirements.
- Support process validation protocols, change control activities, risk assessments, and investigations related to manufacturing processes.
- Monitor process performance through data analysis, statistical tools, and key performance indicators (KPIs); recommend and implement corrective and preventive actions.
- Assist in maintaining formula management systems, ERP/MES systems, and manufacturing master data to ensure process accuracy and consistency.
- Mentor and provide technical guidance to Process Engineers, Engineering Technicians, and cross-functional team members.
- Maintain advanced knowledge of batching, mixing, filling, packaging, and assembly technologies applicable to cosmetic and personal care manufacturing.
- Support regulatory, customer, and internal audits as a technical representative for manufacturing processes.
- Ensure compliance with all safety policies and actively promote a culture of safety and continuous improvement.
- Perform other duties as assigned.
Knowledge, Skills, and Abilities- Bachelor's degree in chemical engineering, Mechanical Engineering, Industrial Engineering, Chemistry, or related technical field required.
- Minimum seven (7) years of manufacturing engineering experience, preferably within cosmetic, personal care, pharmaceutical, food, or other GMP-regulated industries.
- Minimum five (5) years of direct process engineering experience with demonstrated success leading technical projects and process improvement initiatives.
- Strong knowledge of cosmetic Good Manufacturing Practices (GMPs); experience in regulated manufacturing environments required.
- Proven experience with process scale-up, technology transfer, validation, and commercialization of new products.
- Experience evaluating and implementing capital equipment projects and manufacturing technologies.
- Advanced analytical, troubleshooting, and root cause analysis skills.
- Strong understanding of manufacturing processes including mixing, filling, packaging, and assembly operations.
- Experience with Lean Manufacturing, Six Sigma, statistical process control, or continuous improvement methodologies preferred.
- Excellent project management, organizational, and leadership skills.
- Ability to manage multiple complex projects and priorities simultaneously.
- Strong written and verbal communication skills with the ability to present technical information to customers, leadership, and cross-functional teams.
- Proficiency in Microsoft Office applications; experience with ERP, MES, or manufacturing execution systems preferred.
- Demonstrated ability to mentor junior engineers and influence cross-functional teams.
Working Conditions and Physical DemandsThis Job Description is not intended to be an all-encompassing list of responsibilities, skills, efforts, or working conditions associated with this position. It is intended to be a guideline reflecting the essential job functions.
