ZipRecruiter

Log In

1

Senior Process Development Engineer Jobs in Madison, WI

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 ...

Enerpac Tool Group Corp

Lead Process Engineer

Columbus, WI · On-site

$116K - $151K/yr

Lead prototype builds, troubleshooting, and validation activities Manufacturing Process Development ... Strong technical engineering foundation (mechanical + manufacturing) * Proven ability to lead ...

next page

Showing results 1-20

All 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 Jun 26, 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.

Do R&D engineers make good money?

Senior Process Development Engineers typically earn competitive salaries that reflect their specialized skills in process optimization, research, and development. Compensation varies by industry, location, and experience, but they generally earn above-average wages compared to many other engineering roles. Advanced knowledge of tools like statistical analysis and process modeling can also influence earning potential.

Is 40 too late to be an engineer?

Age is not a barrier to becoming a senior process development engineer or any engineering role. Many engineers start or transition into the field later in life, and success depends on skills, experience, and continuous learning, such as gaining relevant certifications or technical expertise. Employers value diverse backgrounds and practical knowledge regardless of age.

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 engineer makes $500,000 a year?

Senior Process Development Engineers in specialized industries such as semiconductor manufacturing or pharmaceuticals can earn $500,000 or more annually, 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 industry certifications.

What engineers make $300,000 a year?

Senior Process Development Engineers in specialized industries such as semiconductor manufacturing, aerospace, or pharmaceuticals can earn $300,000 or more annually, especially with extensive experience, advanced skills, and relevant certifications. High compensation often reflects leadership roles, complex project management, or working in high-demand sectors with competitive salaries.
What are popular job titles related to Senior Process Development Engineer jobs in Madison, WI? For Senior Process Development Engineer jobs in Madison, WI, the most frequently searched job titles are:
What job categories do people searching Senior Process Development Engineer jobs in Madison, WI look for? The top searched job categories for Senior Process Development Engineer jobs in Madison, WI are:
What cities near Madison, WI are hiring for Senior Process Development Engineer jobs? Cities near Madison, WI with the most Senior Process Development Engineer job openings:
Senior Process Development Engineer jobs near you
Infographic showing various Senior Process Development Engineer job openings in Madison, WI as of June 2026, with employment types broken down into 85% Full Time, and 15% Contract. Highlights an 96% In-person, and 4% Hybrid job distribution, with an average salary of $122,058 per year, or $58.7 per hour.
Project Engineer-New Product Development

Project Engineer-New Product Development

Johnson Health Tech North America Inc

Cottage Grove, WI

Other

Posted 29 days ago

Johnson Health Tech rating

8.1

Company rating: 8.1 out of 10

Based on 5 frontline employees who took The Breakroom Quiz

122nd of 419 rated machine equipment manufacturers

Job description

Description


Lead the Development of Innovative Fitness Products

Are you passionate about engineering, product development, and leading cross-functional teams to bring new ideas to life? Join our New Product Development (NPD) team and help drive the creation of innovative fitness equipment used by customers around the world.


As a Project Engineer, you'll serve as the engineering lead and primary liaison between Product Marketing and Factory Manufacturing teams. You'll lead multiple projects through the full product development lifecycle - from concept and design through testing, manufacturing, and production launch.


This is a highly visible role offering the opportunity to collaborate with global teams, influence product direction, and drive engineering excellence across innovative consumer products.


What You'll Do:

Project Leadership & Cross-Functional Collaboration:

Lead cross-functional project teams including R&D, Industrial Design, Factory Engineering, Electrical Engineering, Software Engineering, Quality, and Product Management

Coordinate project scope, schedules, deliverables, and development milestones

Translate customer and market requirements into engineering product specifications and development plans

Communicate regularly with North America-based marketing teams and Asia-based engineering, manufacturing, and quality teams

Facilitate technical design reviews and engineering discussions throughout the product lifecycle


Product Development & Engineering:

Lead multiple projects through the Key Technology/Key Component (KT/KC) and New Product Development (NPD) processes

Drive continuous improvement, value engineering, and design-for-manufacturability initiatives

Support overall engineering design while collaborating with factory engineering teams on detailed CAD development

Participate in DFMEA activities, strength and fatigue analysis, and product validation testing

Ensure engineering documentation, project checklists, and development processes are completed accurately and on schedule


Production Launch & Manufacturing Support:

Support the transition of new products into mass production

Troubleshoot design and manufacturing challenges during production ramp-up

Review product samples, quality data, and inspection feedback to drive product improvements

Partner with factory manufacturing teams to improve product quality, cost efficiency, and manufacturability

Assist global engineering teams with technical requirements and production support

Requirements


Required Qualifications:

Bachelor's degree in Mechanical Engineering or related field

Strong organizational, problem-solving, and project coordination skills

Ability to manage multiple priorities and meet project deadlines

Excellent communication and collaboration abilities

Ability to work effectively with global and cross-functional teams


Preferred Experience:

Internship, co-op, senior design project, or professional experience in mechanical engineering or consumer products

Experience with project engineering or project management

Experience designing production components for manufacturing processes such as:

       o Plastic injection molding

       o Sheet metal fabrication

       o Tube forming

       o Casting

       o Machining

       o Welding and joining


Why Join Us?

Lead projects from concept through production launch

Collaborate with global engineering and manufacturing teams

Work on innovative consumer fitness products

High-visibility role with strong growth potential

Opportunity to influence product quality, performance, and customer experience

Dynamic, team-oriented engineering environment

International travel opportunities available approximately 2-4 times per year based on project needs.



If you're passionate about engineering innovation, product design, and solving real-world challenges, we'd love to hear from you!
  Equal Opportunity Employer, including Protected Veterans and Individuals with Disabilities.

Apply