Merck Co Jobs in Virginia (NOW HIRING)

We have an exciting opportunity for a Senior Process Engineer, Technical Operations - Small Molecule Drug Product (Oral Solid Dose) to join our growing team.

At our company, we aspire to be the premier research‑intensive biopharmaceutical company, using the power of leading‑edge science to save and improve lives around the world. We are at the forefront of research to deliver innovative health solutions that advance the prevention and treatment of diseases in people and animals.

Join a purpose‑built, agile small molecule manufacturing site where your work will help bring important medicines to patients in the U.S. This facility is designed to move quickly and reliably, receiving technology transfers from commercialization sites and fast‑following into production with a focus on quality, safety, and operational excellence.

At our site, you’ll be part of a team committed to creating a safe, environmentally responsible, and compliant workplace where people can do their best work. We are building deep small molecule expertise in the U.S., and we want team members who are excited to grow their skills, help improve how we operate, and contribute to a site positioned for future growth.

The successful candidate will provide technical leadership and process ownership supporting facility design, commissioning, qualification, and startup through to technology transfer, validation, and ongoing commercial manufacture of oral solid dosage forms.

In this role, you will work as a key member of a cross‑functional team, initially supporting the capital project and transitioning into process lead responsibilities across technology transfer and commercial manufacturing, driving technical excellence and operational performance.

• Technical & Process Leadership
  • Provide technical leadership for oral solid dose manufacturing processes:
    • Blending and granulation (where applicable)
    • Roller compaction (dry granulation)
    • Tablet compression
    • Film coating and finishing operations
  • Act as process owner / SME for assigned unit operations, equipment, or product processes
  • Provide technical input to the Capital Project Team, supporting:
    • Equipment selection and design reviews
    • Commissioning and qualification (CQV)
    • Startup readiness for OSD manufacturing lines
  • Lead or coordinate process scale‑up, technology transfer, and validation activities (e.g. PPQ)
  • Analyze and interpret process and product data (e.g. blend uniformity, tablet properties, coating performance) to drive data‑driven decision‑making and performance improvements
  • Provide advanced troubleshooting support for compression, compaction, and coating issues (e.g. weight variability, hardness, sticking/picking, coating defects)
• Technology Transfer & Commercialization
  • Lead or play a key role in execution of technology transfers for oral solid dose products into the facility
  • Partner with global R&D and network sites to ensure robust transfer of formulation and process knowledge
  • Drive:
    • Process fit assessments
    • Scale‑up strategy from development to commercial scale
    • Equipment capability and process comparability assessments
  • Own or guide development and optimization of:
    • Master batch records (MBRs)
    • Process descriptions and control strategies
  • Support integration and industrialization of new formulations and technologies (e.g. continuous manufacturing, advanced granulation approaches where applicable)
• Process Optimization & Operational Excellence
  • Partner with Manufacturing to ensure safe, efficient, and reliable OSD plant performance
  • Identify, prioritize, and implement improvements in:
    • Content uniformity and tablet quality
    • Process robustness (e.g. compaction consistency, compression stability)
    • Yield, throughput, and cycle time
  • Lead or drive continuous improvement initiatives aligned with operational excellence
  • Use structured problem‑solving approaches (e.g. RCA, DOE where applicable) to resolve:
    • Compression issues (e.g. capping, lamination)
    • Compaction variability
    • Coating defects (e.g. color variation, twinning, roughness)
  • Monitor process trends and product quality attributes to proactively identify risks and opportunities
  • Contribute to line optimization, changeover reduction, and debottlenecking activities
• Compliance & Documentation
  • Ensure all activities are conducted in compliance with cGMP, safety, and environmental standards
  • Provide technical leadership in campaign preparation, execution, and post‑campaign review
  • Own and approve batch record updates, process specifications and control strategies
  • Support regulatory inspections and audits, providing technical input and ensuring inspection readiness
  • Ensure high standards of data integrity and technical documentation
• Cross‑functional Collaboration & Influence
  • Act as a technical representative across Manufacturing, Quality, Engineering, Supply Chain, and R&D
  • Provide clear technical direction and influence decision‑making across product introductions and commercial operations
  • Lead or contribute to cross‑functional initiatives, ensuring alignment to timelines and site objectives
  • Support knowledge sharing and best practice transfer across internal and external networks

• Degree in Chemical Engineering, Pharmaceutics, Pharmaceutical Sciences, or related discipline
• Typically 5+ years' experience in oral solid dose manufacturing, formulation, or process development (PhD may offset experience)
• Strong experience in OSD manufacturing operations, particularly:
  • Roller compaction (dry granulation)
  • Tablet compression
  • Film coating processes
• Experience in process scale‑up and commercialization of solid oral dosage forms
• Demonstrated involvement in:
  • Technology transfer
  • Process validation (PPQ)
  • Manufacturing support
• Good understanding of cGMP manufacturing and regulatory expectations
• Experience troubleshooting tableting and coating processes in a commercial environment

• Strong analytical capability with ability to interpret process and product performance data
• Demonstrated ability to lead technical workstreams or projects
• Excellent problem‑solving skills with structured, science‑based approach
• Effective communicator with ability to influence cross‑functional stakeholders
• Proven ability to manage multiple priorities in a dynamic manufacturing environment
• Proactive, self‑driven mindset with strong focus on continuous improvement and ownership

We offer a comprehensive package of benefits. Available benefits include medical, dental, vision, healthcare and other insurance benefits (for employee and family), retirement benefits, including 401(k), paid holidays, vacation, and compassionate and sick days. Additional details are available at https://jobs.merck.com/us/en/compensation-and-benefits.

Salary range: $117,000.00 - $184,200.00. The range is based on education, qualifications, experience, skills, location, and business needs.

We are a federal contractor and provide a paid bonus and long‑term incentives where applicable.

San Francisco Residents Only: We will consider qualified applicants with arrest and conviction records for employment in compliance with the San Francisco Fair Chance Ordinance.

Los Angeles Residents Only: We will consider for employment all qualified applicants, including those with criminal histories, in a manner consistent with the requirements of applicable state and local laws, including the City of Los Angeles' Fair Chance Initiative for Hiring Ordinance.

As an Equal Employment Opportunity Employer, we provide equal opportunities to all employees and applicants for employment and prohibit discrimination on the basis of race, color, age, religion, sex, sexual orientation, gender identity, national origin, protected veteran status, disability status, or other applicable legally protected characteristics. As a federal contractor, we comply with all affirmative action requirements for protected veterans and individuals with disabilities. For more information about personal rights under the U.S. Equal Opportunity Employment laws, visit the EEOC website and related resources. We are proud to be a company that embraces the value of bringing together talented, committed people with diverse experiences, perspectives, skills, and backgrounds.