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Senior Process Development Engineer Jobs in Decatur, IL

Actalent

Industrial Engineer

Sullivan, IL · On-site

$66K - $89K/yr

Industrial / Manufacturing Engineer - CNC Tube Bending This position seeks an Industrial ... process development. * Ability to develop clear work instructions and training materials for ...

ADM

Ethanol Support Engineer - Decatur, IL

Decatur, IL

$90K - $144K/yr

... development and deployment of new technologies and process optimizations.Create, evaluate and ... engineering, or related disciplines).Industry Expertise: 10+ years of hands-on experience in ...

Tanisha Systems

Pinpoint Engineer

Decatur, IL · On-site

Regards Nirdosh Singh Sr. Account Manager | Tanisha Systems Inc. Phone: x 599 Email: [redacted ... We deliver Custom Application Development, Application Modernization, Business Process Outsourcing ...

RFA Engineering

Mechanical Engineer

Decatur, IL · On-site

$65K - $95K/yr

... processes. This position will operate onsite at our customer's world-class engineering and ... Support product development, product improvement, cost reduction, and product health initiatives.

Intellectt INC

Electrical Engineer

Decatur, IL · On-site

Design electrical distribution systems for FMCG/process plants * Perform power system studies and ... Bachelor's or Master's degree in Electrical Engineering Thanks & Regards, Ajay Bhanu Senior ...

AllSTEM Connections

Network Engineer

Decatur, IL · On-site

$176K - $187K/yr

Senior Network Infrastructure Architect (SASE & SD-WAN) Role Overview We are seeking a Senior ... Spearhead the development of an SDN model across Cloud, LAN, WAN, and Wireless platforms. Integrate ...

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Showing results 21-40

All JobsProcess Development Engineer JobsSenior Process Development Engineer JobsSenior Process Development Engineer Jobs in Decatur, IL

Senior Process Development Engineer information

See Decatur, IL salary details

$72.7K

$117.5K

$165.4K

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

As of Aug 7, 2026, the average yearly pay for senior process development engineer in Decatur, IL is $117,479.00, according to ZipRecruiter salary data. Most workers in this role earn between $100,900.00 and $130,500.00 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?

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 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 are popular job titles related to Senior Process Development Engineer jobs in Decatur, IL? For Senior Process Development Engineer jobs in Decatur, IL, the most frequently searched job titles are:
Senior Process Development Engineer jobs near you
Infographic showing various Senior Process Development Engineer job openings in Decatur, IL as of June 2026, with employment types broken down into 1% As Needed, 95% Full Time, 1% Temporary, and 3% Contract. Highlights an 92% Physical, 3% Hybrid, and 5% Remote job distribution, with an average salary of $117,479 per year, or $56.5 per hour.

Industrial Engineer

Actalent

Sullivan, IL • On-site

$66K - $89K/yr

Full-time

Medical, Life, Retirement, PTO

Re-posted 6 days ago

Job description

Job Title: Industrial / Manufacturing Engineer - CNC Tube Bending Job Description This position seeks an Industrial / Manufacturing Engineer with strong expertise in CNC tube bending to design, develop, and optimize metal tube forming processes. The role focuses heavily on advanced tube-bending applications while also supporting broader manufacturing initiatives, including CNC machining, process improvement, and Industry 4.0 adoption. You will work in a hands-on engineering capacity to drive efficiency, quality, and scalability across production operations. Responsibilities
  • Design, program, set up, and optimize CNC tube-bending processes, including rotary draw, ram forming, and push bending, to meet production and quality requirements.
  • Troubleshoot tube-bending defects such as wrinkling, flattening, and spring-back, implementing corrective actions to improve process capability and product consistency.
  • Select, configure, and implement appropriate tooling, including mandrels (plug and ball), wiper dies, and multi-stack tooling, to support a wide range of tube geometries and materials.
  • Apply specialized techniques such as mandrel bending to prevent deformation in tight-radius applications and wiper dies to eliminate wrinkling in thin-wall tubing.
  • Utilize advanced multi-radius bending and multi-stack CNC equipment to produce complex tube parts efficiently and accurately.
  • Support CNC machining programming and integration for mills, lathes, and machining centers as the role evolves, ensuring seamless coordination with tube-bending operations.
  • Lead continuous improvement initiatives using lean manufacturing principles to reduce waste, improve throughput, and enhance overall process efficiency.
  • Optimize equipment layouts, material flow, and workstation ergonomics to improve productivity, safety, and operator comfort on the production floor.
  • Ensure compliance with safety, environmental, and quality standards, including OSHA, ANSI, NFPA, and EPA requirements, and promote a culture of safe work practices.
  • Provide shop floor support by mentoring operators, developing clear work instructions, and resolving production issues in real time.
  • Develop and refine standard operating procedures and process documentation to support repeatable, high-quality manufacturing outcomes.
  • Stay current on emerging technologies such as Industry 4.0, additive manufacturing, and simulation tools, and evaluate opportunities to apply them to manufacturing operations.
  • Collaborate with cross-functional teams in engineering, production, and quality to support new product introductions and ongoing process improvements.
  • Analyze production data to identify trends, root causes of issues, and opportunities for optimization in tube bending and related manufacturing processes.
Essential Skills
  • Bachelor's degree or Associate's degree in Industrial, Manufacturing, Mechanical Engineering, or a closely related field.
  • Minimum of 4+ years of experience in CNC tube bending, including setup, programming, and troubleshooting of tube-bending operations.
  • Strong hands-on experience with CNC tube-bending equipment and processes, including rotary draw, ram forming, and push bending.
  • Proficiency in CAD software such as SolidWorks, AutoCAD, or Inventor for designing tooling, fixtures, and process layouts.
  • Experience with CNC programming using G-code and/or CAM software, or a strong willingness and aptitude to learn CNC programming.
  • Practical knowledge of mandrel bending techniques to prevent deformation in tight-radius tube applications.
  • Ability to apply wiper dies effectively to eliminate wrinkling in thin-wall tubing.
  • Experience working with multi-radius bending and advanced multi-stack CNC equipment for complex tube geometries.
  • Understanding of lean manufacturing principles and their application to process improvement and waste reduction.
  • Ability to interpret engineering drawings, specifications, and technical documentation related to tube forming and machining.
  • Strong problem-solving skills with the ability to diagnose process issues and implement effective corrective actions on the shop floor.
Additional Skills & Qualifications
  • Industrial engineering experience in tubing, CNC programs, and manufacturing engineering.
  • Familiarity with machine programming and integration across mills, lathes, and machining centers.
  • Knowledge of Industry 4.0 concepts and an interest in applying digital tools and data-driven methods to manufacturing operations.
  • Exposure to additive manufacturing and simulation tools and the ability to evaluate their potential use in process development.
  • Ability to develop clear work instructions and training materials for operators and production staff.
  • Strong communication skills for effective collaboration with engineering, production, and quality teams.
  • Organizational skills to manage multiple projects, prioritize tasks, and meet production and engineering deadlines.
Work Environment The work environment is split between an office setting and the production floor, offering a balance of engineering design work and hands-on process support. On the production floor, you will be exposed to typical manufacturing conditions, including noise, temperature variations, and contact with oils and coolants. The role requires regular walking throughout the facility and the ability to lift up to 50 pounds as needed to support equipment setup and troubleshooting. You will work closely with operators, technicians, and other engineers in a collaborative environment that emphasizes safety, continuous improvement, and the adoption of modern manufacturing technologies. Job Type & Location This is a Permanent position based out of Sullivan, IL. Pay and Benefits The pay range for this position is $62400.00 - $83200.00/yr. 2 weeks paid time off, Child care center onsite, and a comprehensive health benefits package focused on wellness rewards along with 401(k) and company paid life insurance. Other benefits include tuition reimbursement earned wage access, discounts, 10 paid holidays, and more! Workplace Type This is a fully onsite position in Sullivan,IL. Application Deadline This position is anticipated to close on Aug 4, 2026. About Actalent Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 20,000 consultants and 5,000 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500. We are proud to be an Engineering News-Record (ENR) Top 500 Design Firm for our engineering design services and a ClearlyRated Best of Staffing winner for both client and talent service. The company is an equal opportunity employer and will consider all applications without regard to race, sex, age, color, religion, national origin, veteran status, disability, sexual orientation, gender identity, genetic information or any characteristic protected by law. If you would like to request a reasonable accommodation, such as the modification or adjustment of the job application process or interviewing process due to a disability, please email actalentaccommodation@actalentservices.com for other accommodation options. San Francisco Fair Chance Ordinance: Pursuant to the San Francisco Fair Chance Ordinance, for all positions located in the city and county of San Francisco, we will consider for employment qualified applicants with arrest and conviction records. Massachusetts Lie Detector: It is unlawful in Massachusetts to require or administer a lie detector test as a condition of employment or continued employment. An employer who violates this law shall be subject to criminal penalties and civil liability. Use of Artificial Intelligence (AI): We may use Artificial Intelligence (AI) to support parts of our hiring process, including sourcing, screening, and evaluating candidates. AI helps assess applications and qualifications, but final decisions are made by our hiring team. By applying, you acknowledge and agree that your application may be reviewed using AI tools.
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About Actalent

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Actalent connects passion with purpose. Our scalable talent solutions and services capabilities drive value and results and provide the expertise to help our customers achieve more. Every day, our experts around the globe are making an impact. We're supporting critical initiatives in engineering and sciences that advance how companies serve the world. Actalent promotes consultant care and engagement through experiences that enable continuous development. Our people are the difference. Actalent is an operating company of Allegis Group, the global leader in talent solutions.

Company size

5,001 - 10,000 Employees

Headquarters location

Hanover, MD, US

Year founded

1983

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