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Senior Process Analyst Jobs in Madison, WI (NOW HIRING)

Mastermold LLC

Paint Process Engineer

Johnson Creek, WI · On-site

$90K - $108K/yr

Perform root cause analysis using tools like 5-Why, Fishbone, PDCA, and implement permanent ... Opportunities for growth into senior process engineering, project engineering, or leadership roles.

Mastermold LLC

Paint Process Engineer

Johnson Creek, WI · On-site

$90K - $108K/yr

Perform root cause analysis using tools like 5-Why, Fishbone, PDCA, and implement permanent ... Opportunities for growth into senior process engineering, project engineering, or leadership roles.

Abbott

Sr. Application Analyst

Madison, WI

The Senior Application Analyst will perform impact analysis of desired changes, build and test ... Develop new processes and procedures to meet current challenges. * Create and maintain system ...

New

Husch Blackwell Llp

Senior Pricing Analyst

Madison, WI · On-site +1

The Senior Pricing Analyst will report to the Associate Director of Strategic Pricing and will ... Support the development and maintenance of team processes, checklists, pricing repository and other ...

SSM Health

Financial Analyst Senior

Madison, WI · On-site

$86K - $107K/yr

As a Financial Analyst Senior , you'll analyze complex financial data, develop forecasts and ... Assists with budget preparation and financial planning processes. Assists with budget review for ...

Quartz

Senior Quality Analyst

Madison, WI · On-site

$66K - $83K/yr

As a Senior Quality Analyst , you'll play a critical role in protecting operational excellence ... Build advanced expertise across multiple business systems and operational processes, including ...

Quartz

Senior Quality Analyst

Madison, WI · Remote

$66K - $83K/yr

As a Senior Quality Analyst , you'll play a critical role in protecting operational excellence ... Build advanced expertise across multiple business systems and operational processes, including ...

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Senior Process Analyst information

See Madison, WI salary details

$30.7K

$91.8K

$125K

How much do senior process analyst jobs pay per year?

As of Aug 24, 2026, the average yearly pay for senior process analyst in Madison, WI is $91,772.00, according to ZipRecruiter salary data. Most workers in this role earn between $79,600.00 and $110,900.00 per year, depending on experience, location, and employer.

What does a senior process analyst do?

A Senior Process Analyst is responsible for evaluating, designing, and improving business processes within an organization. They analyze workflows, identify inefficiencies, and recommend solutions to enhance productivity and reduce costs. Senior Process Analysts often work with cross-functional teams to implement changes, monitor outcomes, and ensure processes align with organizational goals. Their expertise contributes to continuous improvement and operational excellence.

What are some common challenges a senior process analyst may face when implementing process improvements across departments?

A Senior Process Analyst often encounters challenges such as resistance to change from stakeholders, difficulty in aligning diverse departmental goals, and navigating complex organizational structures. Successful analysts use strong communication and facilitation skills to build consensus and ensure everyone understands the benefits of the proposed changes. They also rely on data-driven analysis to demonstrate value and work closely with cross-functional teams to monitor progress and adjust strategies as needed.

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

To thrive as a Senior Process Analyst, you need strong analytical skills, process mapping expertise, and a background in business administration or industrial engineering. Experience with Lean Six Sigma methodologies, process modeling software (such as Visio or ARIS), and relevant certifications like Six Sigma Green Belt are highly valued. Exceptional communication, problem-solving, and stakeholder management skills enable you to drive process improvements and gain buy-in across departments. These capabilities are vital to optimize workflows, increase efficiency, and support organizational change initiatives.

What is the difference between Senior Process Analyst vs Process Analyst?

AspectSenior Process AnalystProcess Analyst
Required CredentialsBachelor's degree, often certifications like Six Sigma or LeanBachelor's degree, similar certifications often preferred
Work EnvironmentSenior-level projects, leadership roles, cross-department collaborationOperational tasks, data analysis, process documentation
Employer & Industry UsageUsed in manufacturing, finance, healthcare, and consulting firmsCommon across same industries, entry to mid-level roles

The main difference between a Senior Process Analyst and a Process Analyst lies in experience, scope of responsibilities, and leadership roles. Senior Process Analysts typically handle more complex projects, mentor junior staff, and contribute to strategic improvements, whereas Process Analysts focus on data collection, process mapping, and supporting operational tasks. Both roles are vital in process improvement initiatives across various industries.

Is a senior process analyst a good career?

A senior process analyst is a valuable role focused on improving business efficiency through analyzing and optimizing processes. It typically requires strong analytical skills, knowledge of process mapping tools, and experience in data analysis or project management. The role offers opportunities for advancement into management or specialized areas within operations or consulting.

What are the most commonly searched types of Process Analyst jobs in Madison, WI?

The most popular types of Process Analyst jobs in Madison, WI are:

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

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

Senior Process Analyst jobs near you
Infographic showing various Senior Process Analyst job openings in Madison, WI as of August 2026, with employment types broken down into 1% As Needed, 76% Full Time, 18% Part Time, 4% Contract, and 1% Nights. Highlights an 92% Physical, 2% Hybrid, and 6% Remote job distribution, with an average salary of $91,772 per year, or $44.1 per hour.

Paint Process Engineer

Mastermold LLC

Johnson Creek, WI • On-site

$90K - $108K/yr

Full-time

Medical, Dental, Vision, Retirement, PTO

Re-posted 17 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.