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Senior Process Development Engineer Jobs in Madison, WI

Collabera

SDET/ Automation Engineer

Madison, WI · On-site

Job Title: SDET/ Automation Engineer Location: Madison, WI or Bellevue, WA Duration: 6 Months ... Develop automated acceptance tests focused around user clinical workflow processes through analysis ...

Sharpe Engineering

Process Engineer

Madison, WI · On-site

Sharpe Engineering & Equipment is seeking an experienced Process Engineer to support the design, development, and execution of sanitary process systems for the food & beverage industry. This hands-on ...

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Senior Process Development Engineer information

See Madison, WI salary details

$75.6K

$122K

$171.8K

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 Madison, WI is $122,040.00, 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?

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 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:
Senior Process Development Engineer jobs near you
Infographic showing various Senior Process Development Engineer job openings in Madison, WI as of August 2026, with employment types broken down into 1% As Needed, 80% Full Time, 15% Part Time, and 4% Contract. Highlights an 92% Physical, 2% Hybrid, and 6% Remote job distribution, with an average salary of $122,040 per year, or $58.7 per hour.

Senior Design Engineer- New Product Development

Sub-Zero Group, Inc.

Madison, WI • On-site

Full-time

Medical, Dental, Vision, Retirement

Re-posted 16 days ago

Job description

Overview
The New Product Development Team is integral to the success of defining and bringing innovative products to market. We are seeking an experienced and technically driven engineer to lead the definition, design, validation and implementation of embedded electromechanical systems for new products and features. Areas of skill and expertise commonly leveraged include embedded system architecture, controls development, electromechanical system design, wire harnessing best practices, and collaborative problem-solving with cross functional groups. As a Senior Design Engineer, you will apply advanced engineering, design, and product development practices to deliver best-in-class luxury appliances.
Continual growth and development are important aspects of this position. If you are motivated by solving complex problems, influencing product definition, and owning part designs through production, this role offers the opportunity to make a significant impact on the future of kitchen appliances.
Primary Responsibilities
  • Facilitate early-phase product definition by collaborating with project management, industrial design, user experience, compliance, reliability, manufacturing, quality, and service stakeholders to develop customer, business, and regulatory needs into clear system-level requirements and constraints.
  • Work with internal and external teams to design, prototype, and implement embedded software, wire harnesses, electromechanical, and thermal subsystems into production-ready, mass-manufacturable products while meeting project deadlines.
  • Evaluate designs through modeling, simulation, benchmarking, laboratory testing, and data analysis.
  • Partner with manufacturing, suppliers, and regulatory teams to ensure system performance, safety, reliability, and cost targets are achieved.
  • Present system architectures and design solutions for review by engineering peers, product teams, and leadership.
  • Mentor engineers in design decisions, integration best practices, and structured problem-solving.

Required Qualifications:
  • Bachelor's or better in Electrical Engineering, Mechanical Engineering or related field.
  • 7+ years: Relevant engineering experience
  • 3+ years: Relevant software, hardware, and/or electromechanical design experience.
  • Proficiency in Solidworks or related CAD software.
  • Strong technical, written, oral, and team communication skills.
  • Code capable in Python, C++ or similar.
  • Applied creativity, proactive approach, and eagerness to overcome development efforts and provide effective/successful design solutions for new products.

Preferred Qualifications:
  • Team and individual experience in approaching new, nuanced, large and/or long-term projects/problems/tasks requiring coordinated planning for success
  • Wire harnessing and system integration.
  • Electromechanical subsystem design.
  • Proficiency in Solidworks Electrical schematic creation and 3D routing.
  • Rapid prototyping

    • Proof-of-concept and/or functional/feasible/testable implementation-of-concept.
    • Quick-turn technologies and tools such as 3D Printing and/or other means of prototyping physical parts/assemblies.
    • Circuit/PCB design/analysis.
    • Embedded programming and/or "input/output" software development.

  • Data capture and analysis.
  • Cloud Computing or IoT implementation.

We value our employees by providing:
  • Competitive compensation based on skills
  • Industry leading health, dental, and vision plans
  • Generous 401 (K) savings and profit sharing
  • On-site UW Health clinic, fitness center, and walking paths
  • Education assistance and internal training programs
  • Electric vehicle charging
  • Maternity & paternity leave
  • Interested in learning more on our robust benefits package we offer? Click here!

This position requires a pre-employment drug/alcohol test and background check, which will be administered after a conditional job offer is extended. A negative drug/alcohol test result is required for employment. Refusal to take the test or a positive result may disqualify a candidate from further consideration. All drug testing will be conducted in accordance with federal and state laws.
Equal Opportunity Employer
This employer is required to notify all applicants of their rights pursuant to federal employment laws.
For further information, please review the Know Your Rights notice from the Department of Labor.

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