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Senior Process Development Engineer Jobs in Milwaukee, WI

Process Technician

Milwaukee, WI · On-site

  • Medical

  • Retirement

Senior Process Technician (Injection Molding) Sector: Tier 1 Automotive & High-Precision ... Scientific Process Development: Establish and maintain robust "decoupled" molding processes ...

Process Technician

Milwaukee, WI · On-site

$30 - $42/hr

  • Medical

  • Retirement

Senior Process Technician (Injection Molding) Sector: Tier 1 Automotive & High-Precision ... Scientific Process Development: Establish and maintain robust "decoupled" molding processes ...

Process Technician

Milwaukee, WI

$30 - $42/hr

  • Medical

  • Retirement

Senior Process Technician (Injection Molding) Sector: Tier 1 Automotive & High-Precision ... Scientific Process Development: Establish and maintain robust "decoupled" molding processes ...

Senior Process Engineer - Milwaukee

Milwaukee, WI · On-site

$102K - $132K/yr

  • Medical

  • Dental

  • Vision

  • Life

  • Retirement

  • PTO

Senior Process Engineers work with clients to produce detailed process designs and simulations for ... Reports To: Operations Director PRIMARY RESPONSIBILITIES Lead development of complex process ...

Sr Process Engineer

Milwaukee, WI

$100K - $140K/yr

  • Medical

  • Life

  • Retirement

S. in Engineering, and a minimum of 2 years experience ... Research and development work will include batch, continuous-batch and continuous processes. The ...

Senior Process Engineer

Waukesha, WI · On-site

$104K - $134K/yr

  • Dental

  • Vision

  • Life

  • Retirement

  • PTO

Process Design & Engineering * Develop and interpret process flow diagrams (PFDs), piping and instrumentation diagrams (P&IDs), and mass/energy balances. * Design and layout fluid process systems and ...

Senior Process Engineer

Waukesha, WI

$104K - $134K/yr

  • Dental

  • Vision

  • Life

  • Retirement

  • PTO

Process Design & Engineering * Develop and interpret process flow diagrams (PFDs), piping and instrumentation diagrams (P&IDs), and mass/energy balances. * Design and layout fluid process systems and ...

Recognize opportunities for improvement in systems or processes, work with the Senior Process ... developmental career path or technical operations. * Engage through situational awareness by ...

Continuously improve the processes, skills, team environment and tools necessary to achieve ... senior management. * Develop and maintain engineering 3D models, BOM's and drawings for Sample ...

Sr. Process / Manufacturing Engineer (SMT)

Germantown, WI · On-site

$105K - $136K/yr

  • Medical

  • Dental

  • Vision

  • Retirement

  • PTO

The Sr. SMT Process / Manufacturing Engineer serves as a technical leader within our electronics ... In addition to supporting new product development (NPD), you'll lead process optimization ...

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Showing results 1-20

Senior Process Development Engineer information

See Milwaukee, WI salary details

$73.9K

$119.3K

$168K

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

As of Aug 18, 2026, the average yearly pay for senior process development engineer in Milwaukee, WI is $119,329.00, according to ZipRecruiter salary data. Most workers in this role earn between $102,500.00 and $132,500.00 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 job categories do people searching Senior Process Development Engineer jobs in Milwaukee, WI look for?

The top searched job categories for Senior Process Development Engineer jobs in Milwaukee, WI are:

What cities near Milwaukee, WI are hiring for Senior Process Development Engineer jobs?

Cities near Milwaukee, WI with the most Senior Process Development Engineer job openings:

Infographic showing various Senior Process Development Engineer job openings in Milwaukee, WI as of August 2026, with employment types broken down into 1% As Needed, 81% Full Time, 15% Part Time, and 3% Contract. Highlights an 91% Physical, 3% Hybrid, and 6% Remote job distribution, with an average salary of $119,329 per year, or $57.4 per hour.

Sr. Extrusion Engineer - Process Development

Cirtec Medical

Sturtevant, WI • On-site

$115K - $135K/yr

Other

Medical, Dental, Vision, Retirement, PTO

This job post has expired 1 day ago. Applications are no longer accepted.


Cirtec Medical rating

6.6

Company rating: 6.6 out of 10

Based on 12 frontline employees who took The Breakroom Quiz


Job description

Description

About us:

For over three decades, Cirtec Medical has been a leading outsourcing partner for complex medical devices. We specialize in providing comprehensive solutions for Class II and III devices, from design and development to precision components and finished device assembly. Our expertise spans neuromodulation, implantable drug delivery, cardiac rhythm management, structural heart, mechanical circulatory support, and minimally invasive surgical systems.

Our dedicated teams prioritize growth, innovation, and collaboration. We actively seek opportunities for improvement to enhance our support for clients. If you embrace a growth mindset and thrive on challenges, you may be a perfect fit for our team!


Position Summary:

The Sr. Engineer, Process Development position is primarily responsible for working in a functional silicone process engineering group within the department, consisting of multiple engineering disciplines. Involved in the design, development, documentation, and validation and of new customer components, and modification of existing products including defining requirements, timelines, and deliverables with a focus on prototypes, process development, design verification, engineering builds, training production, and preparation for process validation and manufacturing transfer of products.

Key Responsibilities:

  • Attends and arranges project meetings to discuss current and future design and development initiatives
  • May serve as a primary contact with clients on projects of moderate complexity.
  • Assist with preparation of proposals and quotations for clients; interface as needed to resolve questions in a timely manner.
  • Assist in preparation and maintaining of project plans to satisfy milestones, deadlines, budgets, and medical device quality regulations with required actions. Track and communicate project status, plans, issues, timelines, action items, and budgets.
  • Serve as the subject matter expert(SME) for silicone extrusion within the Cirtec Plant network.
  • Provide guidance and direction to coworkers on areas of technical expertise.
  • Troubleshoot production processes as required.
  • Evaluate and select appropriate test methods for product requirements.
  • Proficient use of statistical data analysis and DOE in process problem solving and process/product improvement.
  • Collaborate with tooling engineers and tool build center for the design, delivery of effective extrusion tooling
  • Collaborate with material science team and customer on identifying ideal silicones for component design and process optimization.
  • Responsible for the following project inputs:
    • Feasibility builds, documentation, and testing
    • Equipment selection, process development and documentation
    • Device Verification samples and testing
    • Operator training
    • Process Failure Mode Effects Analysis
    • Clinical builds
    • Process Validation
  • Involvement in the full design, development, and validation requirements of projects, including:
    • Product component design and specification creation, including extrusions, molded assemblies, and packaging.
    • Materials sourcing and equipment prototyping.
    • Process verification and validation activities, including data for regulatory submission.
    • Manufacturing transfer and support of existing product lines as applicable.
  • Reliable, consistent, and punctual attendance is an essential function of the job.

Must Have:

  • A Bachelor's degree in a STEM engineering discipline
  • 5 years of experience in process development engineering
  • Experience in an engineering environment with mechanical, tool design, and manufacturing processes (medical device preferred).
  • Must maintain high ethical standards
  • Must demonstrate good organizational skills.
  • Ability to train new engineering employees on project engineering activities and Cirtec policies and procedures.
  • Must be able to read, write and speak fluent English.
  • Strong computer skills, including the MS Office suite and MS Project.
  • Must be able to fully interpret technical drawings, blueprints, specifications, illustrations, and written documents.
  • Strong analytical skills
  • Must be able to obtain and evaluate secondary research information.
  • Ability to learn and apply new technology.
  • Knowledge of engineering principles, technical writing, material properties, good tooling practices, and statistics.
  • Willingness to travel as needed

Salary Range: $115,000 - $135,000 / Annual


Cirtec Medical Corporation considers for employment and hires qualified candidates without regard to age, race, religion, color, sex, sexual orientation, gender identity, national origin, ancestry, protected veteran or disability status or any factor prohibited by law. Cirtec Medical Corporation and all of its related companies fully endorse equal opportunity for all. Cirtec Medical provides reasonable accommodation for qualified individuals with disabilities and disabled veterans in the job application process.


We work to create a culture that is built on innovation, respect, transparency and communication, and hope you take pride in being a member of our team. It is Cirtec's goal to create a great work environment and to keep the company a great place to work. We offer a wide range of benefits, resources, and competitive compensation plans designed to support you at every career and life stage. Our benefits include Training and career development, Healthcare and well-being programs including medical, dental, vision, wellness and occupational health programs, Paid Time Off and 401(k) retirement savings with a company match.


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