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Senior Process Development Engineer Jobs in California

GeneFab

Senior Process Engineer, MSAT

Alameda, CA

$117K - $152K/yr

The Senior Process Engineer will translate scientific insight into robust manufacturing processes ... Collaborate closely with Process Development to evaluate platform candidates, align on scalable ...

GeneFab

Senior Process Engineer, MSAT

Alameda, CA · On-site

$117K - $152K/yr

The Senior Process Engineer will translate scientific insight into robust manufacturing processes ... Collaborate closely with Process Development to evaluate platform candidates, align on scalable ...

GeneFab

Senior Process Engineer, MSAT

Alameda, CA · On-site

$117K - $152K/yr

The Senior Process Engineer will translate scientific insight into robust manufacturing processes ... Collaborate closely with Process Development to evaluate platform candidates, align on scalable ...

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Senior Process Development Engineer information

See California salary details

$74K

$119.5K

$168.3K

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

As of Jul 7, 2026, the average yearly pay for senior process development engineer in California is $119,530.00, according to ZipRecruiter salary data. Most workers in this role earn between $102,600.00 and $132,700.00 per year, depending on experience, location, and employer.

What does a Senior Process Development Engineer do?

A Senior Process Development Engineer is responsible for designing, developing, and optimizing manufacturing processes to improve efficiency, quality, and cost-effectiveness. They often lead teams in scaling up processes from the laboratory to full production, troubleshoot technical issues, and implement new technologies or methods. Additionally, they collaborate with cross-functional teams, including R&D, quality assurance, and production, to ensure processes meet regulatory and safety standards. Their expertise helps companies maintain competitive advantages and meet production goals.

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

To thrive as a Senior Process Development Engineer, you need a strong background in chemical or mechanical engineering, process optimization, and project management, typically supported by a relevant engineering degree. Familiarity with CAD software, process simulation tools (such as Aspen Plus or MATLAB), and Six Sigma or Lean Manufacturing certifications is often required. Excellent problem-solving, leadership, and communication skills help you coordinate cross-functional teams and drive continuous improvement. These skills are crucial for developing efficient, scalable processes that meet quality standards and business goals.

What engineers make $500,000 a year?

Senior Process Development Engineers in specialized industries such as semiconductor manufacturing, aerospace, or pharmaceuticals can reach or exceed a $500,000 annual salary, especially with extensive experience, advanced skills, and leadership roles. High compensation often includes bonuses, stock options, or profit sharing, and requires expertise in process optimization, automation tools, and project management.

Can you make $250,000 as an engineer?

Senior Process Development Engineers in high-demand industries or with extensive experience and specialized skills can earn salaries approaching or exceeding $250,000 annually, especially with bonuses and stock options. However, such compensation levels are typically found in senior roles at large companies or in regions with high living costs, and may require advanced certifications and a strong track record of project success.

What are some common challenges a Senior Process Development Engineer may face when scaling up a new process from the lab to full production?

Senior Process Development Engineers often encounter challenges such as maintaining product quality and consistency when transitioning from small-scale laboratory experiments to large-scale manufacturing. This process typically involves troubleshooting equipment limitations, optimizing process parameters, and ensuring compliance with safety and regulatory standards. Effective collaboration with cross-functional teams, such as R&D, manufacturing, and quality assurance, is crucial to address these challenges and achieve a smooth scale-up. Adaptability and problem-solving skills are essential to navigate unexpected issues that may arise during this transition.

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

AspectSenior Process Development EngineerProcess Engineer
CredentialsBachelor's or Master's in Chemical, Mechanical, or Industrial Engineering; experience in process developmentBachelor's degree in Engineering or related field; entry to mid-level experience
Work EnvironmentResearch and development labs, manufacturing facilities, cross-functional teamsManufacturing plants, production lines, process optimization teams
Industry UsagePharmaceuticals, chemicals, biotech, manufacturingManufacturing, chemical processing, consumer goods

The main difference is that Senior Process Development Engineers focus on developing and optimizing new processes, often in R&D settings, while Process Engineers typically oversee existing manufacturing processes to improve efficiency and quality. Senior roles involve more strategic planning and innovation, whereas Process Engineers focus on day-to-day process operations.

What engineers make $200,000 a year?

Senior Process Development Engineers in industries such as semiconductor, pharmaceutical, or aerospace often earn $200,000 or more annually, especially with extensive experience, specialized skills, and advanced certifications. Compensation can vary based on location, company size, and individual expertise, with some roles including bonuses and stock options.

What engineers make $300,000 a year?

Senior Process Development Engineers in industries like semiconductor manufacturing, aerospace, or pharmaceuticals can earn $300,000 or more annually, especially with extensive experience, specialized skills, and advanced certifications. High compensation often includes bonuses, stock options, or other incentives, particularly in competitive or high-demand sectors.
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Senior Process Development Engineer jobs near you
Infographic showing various Senior Process Development Engineer job openings in California as of July 2026, with employment types broken down into 1% As Needed, 82% Full Time, 14% Part Time, 1% Temporary, and 2% Contract. Highlights an 92% Physical, 2% Hybrid, and 6% Remote job distribution, with an average salary of $119,530 per year, or $57.5 per hour.
Senior NPI Process Development Engineer

Senior NPI Process Development Engineer

Neptune Medical

Burlingame, CA • On-site

$140K - $175K/yr

Full-time

Retirement

Posted 27 days ago

Job description

Neptune Medical, is an innovative, venture capital funded medical device startup headquartered in Burlingame, CA. We have already commercialized novel medical devices using our technology. Now the team at Neptune is building something truly unique: a fully flexible medical robot that enables doctors to reach deep into human anatomy. Triton Robotic Endoscopy will disrupt flexible endoscopy and set a new standard in outcomes for decades to come.
TITLE: Senior NPI Process Development Engineer
POSITION SUMMARY:
The Senior NPI Process Development Engineer will focus on further developing our product and then transferring it into a manufacturing setting. The successful candidate will possess a passion for medical device engineering and a record of successful process, tooling and equipment design. This role will engage in cross-functional collaboration to accelerate the product development process, reduce cost of goods, and enable more complex designs through manufacturing improvements.
The ideal candidate will act with passion and intensity in a medical device start-up that is fast paced and collaborative and will display the ability to perform to the requirements outlined below. For the right person, this position will be a tremendously exciting and career-defining opportunity, making core contributions to a genuinely new type of medical robotic platform.
ROLES AND RESPONSIBILITIES:
  • Work with product development to design and prototype novel manufacturing processes and equipment
  • Develop new processes to manufacture our products to meet device performance and cost targets.
  • Design and prototype novel manufacturing equipment and fixturing
  • Create and maintain necessary Manufacturing Process Instructions (MPI's), test methods, product drawings, and component specifications
  • Upgrade our manufacturing processes to ensure proper DFM and maximum scalability of our medical devices
  • Initiate and implement programs to continuously improve quality, cost and cycle time
  • Prototype fixtures using 3-D printers, lathe, drill press, band saw, etc.
  • Provides technical support and performing failure analysis for non-conforming components, assemblies, and process defects
  • Build the assembly line for our clinical launches
  • Specify, support and maintain the proper CER space to manufacture our medical devices under defined environmental quality controls.
  • Manage the flow of WIP through Lean practices including Kanban and 5S.
  • Maintain relationships with key vendors and suppliers and support supplier validations and supplier management best practices.
  • Emphasize quality and utilize a risk-driven approach to ensure compliance to risk management policies and practices and ensure GMP.
  • Support company goals and objectives, policies and procedures that comply with FDA Quality System Regulations (QSR), ISO 13485, and any other applicable domestic regulations including Cal FDB, OSHA and Cal-OSHA.

REQUIRED QUALIFICATIONS:
  • B.S. or M.S. in Mechanical or Related Engineering
  • 4+ years of work experience
  • Demonstrated experience working with cross functional teams.
  • Proven track record of generating and managing manufacturing documentation from concept to commercialization for medical device product (MPIs, LHRs, BOM, flowcharts, etc.)
  • Capable with CAD modeling, engineering drawing generation, DFM, tolerance analysis and tooling design
  • Possess knowledge of process validation, GMP, and state-of-the-art manufacturing processes
  • A driven outlook and with a strong desire to succeed as an engineer, as a team, and as a company.
  • Solid understanding of design controls
  • Demonstrated success developing catheter manufacturing processes including braiding, coil winding, extruding, lamination, adhesive joining, die bonding, and laser welding.

PREFERRED QUALIFICATIONS:
  • Experience with catheter or similar manufacturing (lamination, bonding, dip coating, ultrasonic welding, etc)
  • Experience with disposables/consumables
  • Experience managing lab technicians and assemblers.
  • Developed products from invention to market release.
  • Experience in a start-up environment.
  • Proficient with SolidWorks.
  • Experience creating and managing schedules, budgets, and plans.
  • Experience with packaging and shipping validations

Neptune Medical is located in Burlingame, CA, near the Millbrae Caltrain and BART station.
Our job titles may span more than one career level. The starting base salary for this role is between $140,000 and $175,000 depending on experience. The actual base pay is dependent upon many factors, such as: education, training, transferable skills, work experience, business needs, and location. The base pay range is subject to change and may be modified in the future. This role may also be eligible for equity, benefits and 401(K) with matching.
Neptune Medical provides equal employment opportunities to all applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state or local laws.

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