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$52.2K

$116.5K

$174.8K

How much do process development engineer jobs pay per year?

As of May 29, 2026, the average yearly pay for process development engineer in Hayward, CA is $116,497.00, according to ZipRecruiter salary data. Most workers in this role earn between $92,300.00 and $136,400.00 per year, depending on experience, location, and employer.

What Is a Process Development Engineer?

A process development engineer designs and plans production systems to be cost-effective, safe, and meet quality requirements for their industry. These professionals often work as part of a quality assurance team or a production management department for industrial companies, such as manufacturing or mining businesses. As a process development engineer, your job duties include reviewing the company's current production processes and designing modifications to the current system or creating new systems to increase productivity. Once you have installed or implemented the system, you make sure to test and troubleshoot it to ensure they run properly.

What are the key skills and qualifications needed to thrive as a Process Development Engineer, and why are they important?

To thrive as a Process Development Engineer, you need a solid foundation in engineering principles, process optimization, and problem-solving, typically supported by a degree in chemical, mechanical, or industrial engineering. Familiarity with process simulation software (such as Aspen Plus or MATLAB), Six Sigma methodologies, and relevant industry certifications is often required. Strong analytical thinking, effective communication, and teamwork skills help you excel in cross-functional projects and drive continuous improvement. These skills and qualities are crucial for designing efficient processes, ensuring product quality, and supporting organizational competitiveness.

What are some common challenges faced by Process Development Engineers when scaling up from laboratory to production environments?

One of the main challenges Process Development Engineers encounter is ensuring that processes which work efficiently at a laboratory scale can be reliably and safely replicated in full-scale manufacturing. Differences in equipment size, process dynamics, and raw material variability can lead to unforeseen issues such as inconsistent product quality or unexpected safety hazards. Effective communication and collaboration with both R&D and production teams are essential to troubleshoot problems and optimize process parameters. Engineers often need to adapt quickly, apply problem-solving skills, and implement robust validation protocols to ensure successful scale-up.

What does a Process Development Engineer do?

A Process Development Engineer is responsible for designing, developing, and optimizing manufacturing processes to improve efficiency, quality, and cost-effectiveness. They often work in industries such as pharmaceuticals, chemicals, or electronics, collaborating with cross-functional teams to scale up processes from the lab to full production. Their role includes troubleshooting process issues, implementing new technologies, and ensuring compliance with safety and regulatory standards. By constantly refining processes, they help companies maintain competitive advantages and meet production goals.

What is the difference between Process Development Engineer vs Manufacturing Engineer?

AspectProcess Development EngineerManufacturing Engineer
Primary FocusDesigning and optimizing manufacturing processes for new productsOverseeing and improving existing manufacturing processes
Work EnvironmentR&D labs, pilot plants, early-stage productionProduction floors, plant operations
Required CredentialsBachelor's or higher in engineering, experience in process designBachelor's or higher in engineering, experience in manufacturing
Industry UsagePharmaceuticals, electronics, chemicals, biotechAutomotive, consumer goods, electronics, industrial manufacturing

While both roles involve process optimization, Process Development Engineers focus on creating and refining new manufacturing processes, often in early development stages. Manufacturing Engineers typically work on maintaining and improving existing production processes to ensure efficiency and quality in ongoing operations.

More about Process Development Engineer jobs
What are popular job titles related to Process Development Engineer jobs in Hayward, CA? For Process Development Engineer jobs in Hayward, CA, the most frequently searched job titles are:
What job categories do people searching Process Development Engineer jobs in Hayward, CA look for? The top searched job categories for Process Development Engineer jobs in Hayward, CA are:
What cities near Hayward, CA are hiring for Process Development Engineer jobs? Cities near Hayward, CA with the most Process Development Engineer job openings:
Process Development Engineer jobs near you
Sr Process Development Engineer

Sr Process Development Engineer

Imperative Care

Campbell, CA • On-site

Full-time

Medical, Retirement, PTO

Posted 5 days ago

Job description

Title: Sr Process Development Engineer
Location: This position is full time and on-site in Campbell, CA
Why Imperative Care?
Do you want to make a real impact on patients? Imperative Care is changing the way stroke and vascular diseases are treated. As part of our team, you’d be supporting breakthroughs that will revolutionize the future of stroke care. Every day, the technologies that we develop at Imperative Care directly impact human lives. Our focus is on the needs of the patient, and they come first in everything we do.
What You’ll Do
As a senior professional in this field, this position will contribute to product development projects by defining, characterizing, optimizing, and validating stable, robust, and capable processes for neuro-interventional medical devices. This role will develop and improve internal equipment and manufacturing processes including qualification of processes at external suppliers/contract manufacturers sites. This position uses demonstrated experience to contribute to design process characterization studies by analyzing, interpreting and documenting/reporting data, and documenting effectiveness of equipment/processes.
  • Prepare and implement improvements to the design, selection, characterization, optimization, validation, documentation, and control all manufacturing processes. Define and measure critical process parameters (CPP) that impact critical quality attributes (CQA) of a product, along with cross-functional teams.
  • Spearhead the development and improvement of new/existing processes.
  • Initiate innovation by identifying and selecting new process technologies including defining, developing, and qualifying new equipment/fixtures or improving existing equipment/ fixtures.
  • Identify and recommend solutions to improve performance by employing analytical techniques and engineering principles to understand impact/interaction of materials and processes on outputs.
  • Develop with a cross-functional team process windows, manufacturing control limits, manufacturing workflows, effectively monitoring control plans, lot history records and workmanship standards.
  • Define manufacturable product design specifications and visual standards.
  • Design, execute, test, and analyze results from DOEs providing guidance/insights to collaborating team.
  • Plan and make data-driven decisions by applying DMAIC principles to find root cause/solve problems.
  • Document equipment and process performance and compliance.
  • Participate in overseeing and qualifying external suppliers

What You’ll Bring
  • Bachelor’s degree in engineering or related discipline and a minimum of 5 years of related experience; or equivalent combination of education and work experience in the medical device or related regulated industry.
  • Ability to perform computer modelling simulations on material, process & properties.
  • Experience in pilot and production line set-up, validation and scale-up in a controlled environment.
  • Experience with GMP, GDP procedures and requirements.
  • Excellent analytical and statistical skills (SPC, DOEs) using Excel, Minitab &/or JMP.
  • Excellent knowledge of and experience in FDA Design Control procedures and DFSS/DFM tools.
  • Experience working under quality systems designed to meet governmental regulations such as FDA QSR, ISO 13485, the MDD, and knowledge of relevant standards.
  • Excellent project management and communications skills (both written and verbal).
  • Exceptional critical thinking – able to intuitively identify problems, logically and empirically associate cause and effect, and under a variety of perspectives and constraints, prioritise and provide creative, effective, and practical solutions.
  • Working knowledge of Agile scrum framework, a plus.
  • Ability to work independently and influence others in team setting with/without authority.
  • Able to share knowledge and mentor/guide others in work related to this filed.
  • Ability to travel – as required.

Employee Benefits include a stake in our collective success with stock options, bonus, competitive salaries, a 401k plan, health benefits, generous PTO, and a parental leave program.
Salary Range: $125,000 – 136,000 annually
Please note that the salary information is a general guideline only. Imperative Care considers factors such as scope and responsibilities of the position, candidate's work experience, education/training, key skills, and internal equity, as well as location, market and business considerations when extending an offer
Join Us! Imperative Care
The posted salary range reflects compensation for employees based in the local Bay Area market. For candidates hired outside of this geographic area, compensation may vary and be adjusted based on location, local market conditions, and other factors
 

The use of external recruiters/staffing agencies requires prior approval from our Human Resources Department. The Human Resources Department at Imperative Care requests that external recruiters/staffing agencies not to contact Imperative Care employees directly in an attempt to present candidates. Complying with this request will be a factor in determining future professional relationships with Imperative Care.

Imperative Care will not accept unsolicited resumes from any source other than candidates themselves for either current or future positions. Submission of unsolicited resumes in advance of an agreement between the Human Resources Department and the external recruiter/staffing agency does not create any implied obligation on the part of Imperative Care.

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