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Senior Manufacturing Process Engineer Jobs in Madison, WI

Mastermold LLC

Paint Process Engineer

Johnson Creek, WI · On-site

$90K - $108K/yr

Bachelor's degree in Chemical, Mechanical, Industrial, or Manufacturing Engineering OR equivalent ... Opportunities for growth into senior process engineering, project engineering, or leadership roles.

Family Fresh Pack Inc

Process Engineer

Monticello, WI · On-site

The Process Engineer is responsible for identifying and implementing manufacturing improvements that drive safety, quality, efficiency, yield, and profitability. This role partners closely with ...

Family Fresh Pack Inc

Process Engineer

Monticello, WI · On-site

$70K - $85K/yr

The Process Engineer is responsible for identifying and implementing manufacturing improvements that drive safety, quality, efficiency, yield, and profitability. This role partners closely with ...

Family Fresh Pack Inc

Process Engineer

Monticello, WI · On-site

$70K - $85K/yr

The Process Engineer is responsible for identifying and implementing manufacturing improvements that drive safety, quality, efficiency, yield, and profitability. This role partners closely with ...

Family Fresh Pack Inc

Process Engineer

Monticello, WI · On-site

The Process Engineer is responsible for identifying and implementing manufacturing improvements that drive safety, quality, efficiency, yield, and profitability. This role partners closely with ...

Fresh Pack Wisconsin

Process Engineer

Monticello, WI · On-site

$70K - $85K/yr

The Process Engineer is responsible for identifying and implementing manufacturing improvements that drive safety, quality, efficiency, yield, and profitability. This role partners closely with ...

Freshpack

Process Engineer

Monticello, WI · On-site

$70K - $85K/yr

The Process Engineer is responsible for identifying and implementing manufacturing improvements that drive safety, quality, efficiency, yield, and profitability. This role partners closely with ...

Latitude Corp.

Machining Process Engineer

Verona, WI · On-site

Develop and maintain efficient manufacturing processes and procedures. * Participate and/or lead ... Collaborate with quality and sales engineering to ensure that products meet quality and safety ...

Latitude Corp.

Machining Process Engineer

Verona, WI · On-site

Develop and maintain efficient manufacturing processes and procedures. * Participate and/or lead ... Collaborate with quality and sales engineering to ensure that products meet quality and safety ...

Promega

Process Engineer Co-op

Madison, WI · On-site

The Process Engineering team is made up of Process Engineers and Automation Engineers with varied ... manufacturing processes for ongoing continuous improvement in the areas of reliability, cost ...

Kosmos

Process Engineer

Mcfarland, WI · On-site

$110K - $140K/yr

Growing Manufacturing Company in Butte, Montana has a need for a Process Engineer. This is a direct hire role with a full benefits package and relocation. Prefer a B.S. in Engineering, and a minimum ...

Promega

Process Engineer Co-op

Madison, WI · On-site

The Process Engineering team is made up of Process Engineers and Automation Engineers with varied ... manufacturing processes for ongoing continuous improvement in the areas of reliability, cost ...

Menasha Corporation

Process Engineer

De Forest, WI · On-site

About The Opportunity Design and implement manufacturing processes, equipment and plants (pilot to ... Degree in related Engineering field Experience to be considered in lieu of education Work ...

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Showing results 21-40

All JobsManufacturing Process Engineer JobsSenior Manufacturing Process Engineer JobsSenior Manufacturing Process Engineer Jobs in Madison, WI

Senior Manufacturing Process Engineer information

See Madison, WI salary details

$75.6K

$122K

$171.8K

How much do senior manufacturing process engineer jobs pay per year?

As of Sep 4, 2026, the average yearly pay for senior manufacturing process engineer in Madison, WI is $122,040.00, according to ZipRecruiter salary data. Most workers in this role earn between $104,800.00 and $135,500.00 per year, depending on experience, location, and employer.

What does a senior manufacturing process engineer do?

A Senior Manufacturing Process Engineer is responsible for designing, analyzing, and improving manufacturing processes to increase efficiency, quality, and safety in production environments. They lead projects to implement new technologies, troubleshoot process issues, and optimize workflows. They also work closely with cross-functional teams to ensure that products meet industry standards and regulatory requirements. Additionally, they mentor junior engineers and support continuous improvement initiatives within the organization.

What are the main challenges a senior manufacturing process engineer faces when implementing process improvements?

One of the primary challenges Senior Manufacturing Process Engineers encounter is balancing the need for process innovation with maintaining production efficiency and product quality. Implementing new technologies or methodologies often requires extensive cross-functional collaboration, training, and sometimes overcoming resistance to change from team members. Additionally, ensuring that process improvements comply with industry regulations and safety standards can add complexity. However, these challenges provide valuable opportunities to develop leadership skills and drive significant impact within the organization.

What are the key skills and qualifications needed to thrive as a senior manufacturing process engineer, and why are they important?

To thrive as a Senior Manufacturing Process Engineer, you need a strong background in engineering principles, process optimization, and manufacturing systems, typically with a bachelor's or master's degree in engineering and relevant industry experience. Familiarity with CAD/CAM software, Lean Six Sigma methodologies, and statistical process control tools is highly valued, along with certifications such as Six Sigma Green or Black Belt. Exceptional problem-solving abilities, leadership, and effective communication are crucial soft skills for driving process improvements and collaborating across teams. These skills ensure efficient production, high product quality, and continuous operational enhancements in a competitive manufacturing environment.

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

AspectSenior Manufacturing Process EngineerManufacturing Engineer
Required CredentialsBachelor's degree in engineering, 5+ years experience, possibly certifications like Six SigmaBachelor's degree in engineering or related field, 1-3 years experience
Work EnvironmentOversees process improvements, leads projects, collaborates with cross-functional teamsSupports manufacturing operations, implements process changes, troubleshoots production issues
Employer & Industry UsageUsed in manufacturing plants, automotive, aerospace, electronics industriesCommon in similar industries, entry to mid-level roles in manufacturing

The main difference is that a Senior Manufacturing Process Engineer typically has more experience, takes on leadership roles, and oversees complex process improvements, while a Manufacturing Engineer focuses on supporting and implementing manufacturing processes at a more operational level.

What are popular job titles related to Senior Manufacturing Process Engineer jobs in Madison, WI?

For Senior Manufacturing Process Engineer jobs in Madison, WI, the most frequently searched job titles are:

What job categories do people searching Senior Manufacturing Process Engineer jobs in Madison, WI look for?

The top searched job categories for Senior Manufacturing Process Engineer jobs in Madison, WI are:

What cities near Madison, WI are hiring for Senior Manufacturing Process Engineer jobs?

Cities near Madison, WI with the most Senior Manufacturing Process Engineer job openings:

Senior Manufacturing Process Engineer jobs near you
Infographic showing various Senior Manufacturing Process Engineer job openings in Madison, WI as of August 2026, with employment types broken down into 1% As Needed, 77% Full Time, 17% Part Time, 4% Contract, and 1% Nights. Highlights an 92% Physical, 2% Hybrid, and 6% Remote job distribution, with an average salary of $122,040 per year, or $58.7 per hour.

Paint Process Engineer

Mastermold LLC

Johnson Creek, WI • On-site

$90K - $108K/yr

Full-time

Medical, Dental, Vision, Retirement, PTO

Re-posted 28 days ago

Job description


We’re looking for Paint Process Engineers to own, stabilize, and improve our paint and coating processes. This role is less about “babysitting the line” and more about building robust processes that run right the first time, every time.

You’ll define standards, dial in parameters, reduce defects, and lead continuous improvement so production, quality, and maintenance have a repeatable, capable process to work with.


What You’ll Do

Process Engineering & Standardization

  • Develop, document, and maintain paint process standards (parameters, recipes, and work instructions) for existing and new products.

  • Define and optimize: gun settings, atomizing air, film build targets, flash/bake times, oven profiles, line speeds, and booth balance.

  • Build and maintain control plans, standardized work, and process check sheets for paint operations.

  • Use data (SPC, Pareto, capability studies) to identify variation and tighten up the process.

Defect Reduction & Root Cause Analysis

  • Lead structured problem-solving for paint defects (runs, sags, orange peel, dry spray, fisheyes, adhesion issues, color shifts, etc.).

  • Perform root cause analysis using tools like 5-Why, Fishbone, PDCA, and implement permanent corrective actions.

  • Partner with Quality to monitor scrap, rework, and first-pass yield, and drive projects to reduce defects.

Launches, Trials & Process Changes

  • Lead process development for new colors, coatings, or products—from lab trials to full production.

  • Plan and run process trials and DOE to evaluate new materials, equipment, and parameter changes.

  • Support PPAPs and customer approvals by preparing data, documentation, and sample runs as needed.

Cross-Functional Collaboration

  • Work closely with Production, Maintenance, Engineering, and Quality to ensure the paint process is understood, stable, and repeatable.

  • Train supervisors, leads, and operators on proper application techniques, defect recognition, and process controls.

  • Collaborate with Maintenance/Engineering on equipment upgrades, nozzle/robot changes, and oven/booth improvements.

Safety & Compliance

  • Ensure paint processes meet safety, environmental, and regulatory requirements.

  • Support safe storage, handling, and usage of paints, solvents, and chemicals used in the process.


What You Bring

Required

  • Bachelor’s degree in Chemical, Mechanical, Industrial, or Manufacturing Engineering
    OR equivalent hands-on experience in paint/coatings process engineering.

  • Direct experience with industrial painting or coating operations (automotive, heavy truck, agriculture, metal finishing, composites, etc.).

  • Strong process engineering mindset: comfortable with data, parameters, standardized work, and root cause analysis.

  • Ability to operate on the production floor, communicate with operators, and present clearly to leadership.

  • Proficiency with Excel and basic data analysis for reporting and process monitoring.

Preferred

  • Experience with powder coating, liquid paint, or gel coat systems, including pretreatment and curing ovens.

  • Familiarity with DFT measurement, gloss/color measurement, adhesion testing, and cure verification.

  • Experience with robotic application equipment and/or automated paint lines.

  • Exposure to Lean, Six Sigma, PFMEA, control plans, and CI projects in a manufacturing environment.


What We Offer

  • Competitive salary and performance-based bonus opportunity.

  • Comprehensive benefits package ([health/dental/vision/401(k)/etc.]).

  • Paid time off and holidays.

  • Opportunities for growth into senior process engineering, project engineering, or leadership roles.

  • A visible impact: you’ll see your process changes show up directly as better quality, less scrap, and smoother production.