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Senior Process Development Engineer Jobs in Madison, WI

Zimmer, Inc.

Manufacturing Sr Engineer I

Madison, WI · On-site

$91K - $125K/yr

What You Can Expect The senior manufacturing engineer is responsible for providing manufacturing ... Engineering services may include cell management, process development, project management, process ...

SHINE Technologies LLC

Senior R&D Chemist

Janesville, WI · On-site

$75K - $120K/yr

The role of the Senior R&D Chemist plays a critical part in radiochemical process development and ... Work closely with multidisciplinary teams in chemistry, process engineering, and licensing to ...

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All JobsProcess Development Engineer JobsSenior Process Development Engineer JobsSenior Process Development Engineer Jobs in Madison, WI

Senior Process Development Engineer information

See Madison, WI salary details

$75.6K

$122.1K

$171.8K

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

As of Jul 17, 2026, the average yearly pay for senior process development engineer in Madison, WI is $122,058.00, 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 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
Product Development Engineer - Middleton, WI

Product Development Engineer - Middleton, WI

Spectrum Brands

Middleton, WI • On-site

$60K - $80K/yr

Full-time

Posted 15 days ago

Spectrum Brands rating

6.3

Company rating: 6.3 out of 10

Based on 10 frontline employees who took The Breakroom Quiz

Job description

Division Information
Spectrum Brands' Home & Personal Care (HPC) Appliances business participates on a global basis in small electric appliances, shave/groom appliances and beauty appliances. Our well- known brands include George Foreman®, Black+Decker®, Farberware®, Breadman®, Juiceman®, Russell Hobbs® and Remington®. Our products appeal to consumer trends for healthy eating, stay-at-home cooking, creating today's new hair style and much more. We distinguish our product offerings from the competition by employing forward thinking, innovative technologies matched with a strong understanding of consumer needs to bring to market high quality, superior products that delight the end user.
Job Summary
Location: Middleton, WI (Hybrid - In Office Tuesday through Thursday)
Salary Range: $60,000 - $80,000
No current or future sponsorship available.
Spectrum Brands is seeking a Product Development Engineer to help bring innovative small appliances from concept to retail shelves. This is an excellent opportunity for an early-career mechanical engineer who enjoys solving technical challenges, working with cross-functional teams, and seeing products evolve from idea to production.
This position is designed for:
  • Candidates with approximately 0-5 years of experience
  • Individuals with 3D modelling software experience (SolidWorks, Fusion 360, or similar)
  • Engineers with a passion for product design, innovation, and consumer products
  • Strong communicators who enjoy collaborating across multiple teams and functions
  • Candidates looking for a role that combines technical engineering work with exposure to the full product lifecycle, from concept through commercialization

Primary Duties & Responsibilities
Product Strategy & Planning
  • Supports development of product roadmaps and category initiatives
  • Assists in gathering and organizing consumer insights, competitive benchmarking, and product data
  • Contributes to product definition activities, including features, specifications, and supporting documentation

Product Development Execution
  • Leads projects through the Stage-Gate process, ensuring execution against defined scope, cost, schedule, and performance targets.
  • Supports development of product requirements, specifications, and validation plans.
  • Assists with prototype evaluation, product testing, and performance validation activities.
  • Supports cross-functional alignment and follows up on milestones and deliverables.

Cross-Functional Coordination & Communication
  • Coordinates with R&D, Industrial Design, Sourcing, Quality, and Marketing to support project execution.
  • Supports preparation for gate reviews, presentations, and cross-functional meetings.
  • Communicates project status and escalates risks or issues as needed.

Continuous Improvement & Execution
  • Supports improvements to NPD processes, tools, and documentation.
  • Maintains accurate documentation and project records.
  • Contributes to improving execution efficiency across projects.
  • Identifies and mitigates technical, supply, cost, and regulatory risks.

Other
  • Travel 1-2 times per year internationally for project collaboration and product trend evaluation.

Education and Experience Profile
  • Bachelor's degree in Engineering or related field required.
  • 0-5 years of experience in product development, engineering, or related roles.
  • Exposure to consumer products or retail-driven environments preferred.
  • Familiarity with Stage-Gate or structured product development processes.

Required Skills
  • Basic understanding of product development processes and cross-functional workflows.
  • Ability to lead smaller scope projects and execute assigned tasks with accuracy and attention to detail.
  • Strong technical aptitude and ability to support testing and product evaluation.
  • Ability to gather, analyze, and summarize technical and business data.
  • Structured problem-solving approach with ability to identify issues and escalate appropriately.
  • Ability to work effectively within cross-functional teams.
  • Clear written and verbal communication skills.
  • Willingness to learn, take direction, and incorporate feedback.
  • Proficient with 3D modelling software (Solidworks or Fusion preferred).

Work Environment
Working conditions are normal for an office environment.
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