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Senior Process Development Engineer Jobs in Milwaukee, WI

DR Power LLP

Senior Windchill Process Owner

Waukesha, WI · On-site

$150 - $200/hr

This role is dedicated to optimizing CAD/PLM tools to streamline engineering design, analysis, product development, and product maintenance processes. The Senior PLM Process Adoption Lead identifies ...

Generac

Senior Windchill Process Owner

Waukesha, WI · On-site

$104K - $134K/yr

As our Senior Windchill Process Owner , you will lead the strategy, optimization, and adoption of ... Experience supporting product development, engineering change, and product release processes.

Generac

Senior Software Development Engineer

Sussex, WI · On-site

$119K - $157K/yr

The Senior Software Development Engineer is a senior member of a team developing and testing power generation control systems that can be remotely controlled and monitored using web and mobile ...

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

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 Sep 8, 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 are popular job titles related to Senior Process Development Engineer jobs in Milwaukee, WI?

For Senior Process Development Engineer jobs in Milwaukee, WI, the most frequently searched job titles are:

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:

Senior Process Development Engineer jobs near you
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, 78% Full Time, 19% Part Time, and 2% Contract. Highlights an 86% Physical, 3% Hybrid, and 11% Remote job distribution, with an average salary of $124,875 per year, or $60 per hour.

Sr. Process / Manufacturing Engineer (SMT)

J.W. Speaker

Germantown, WI • On-site

$105K - $136K/yr

Full-time

Medical, Dental, Vision, Retirement, PTO

Re-posted 9 days ago

Job description

ABOUT THE POSITION: The Sr. SMT Process / Manufacturing Engineer serves as a technical leader within our electronics manufacturing operation, partnering closely with Engineering, Quality, Production, and Supply Chain to bring new products from concept through production. This role is responsible for ensuring designs are manufacturable, scalable, and capable of meeting safety, quality, delivery, and cost objectives.
In addition to supporting new product development (NPD), you'll lead process optimization initiatives across our SMT operation, analyzing performance data, reducing defects and scrap, improving cycle times, and evaluating new technologies that enhance manufacturing capability. This position combines strategic project leadership with hands-on engineering work, making it ideal for someone who enjoys solving complex technical challenges while influencing the future direction of manufacturing.
OUR IDEAL CANDIDATE: You're a hands-on manufacturing professional with a Bachelor's degree in Mechanical, Industrial, Manufacturing Engineering, or a related field and 8+ years of experience in a manufacturing environment, preferably SMT. You have a strong background in new product introduction, Design for Manufacturability (DFM), process optimization, and continuous improvement, with the ability to identify opportunities to improve quality, throughput, and cost.
Experience with SMT manufacturing processes and equipment is highly desirable, including an understanding of solder paste printing, component placement, reflow, inspection, and process controls. You're a data-driven problem solver who can influence cross-functional teams, drive improvements, and support decisions related to process changes, capital equipment, and new technologies.
HOW YOU WILL MAKE A DIFFERENCE:
You will INNOVATE by:
  • Collaborating, leading, defining, and implementing design for manufacturing principles on new and current product initiatives cross-functionally to improve Safety, Quality, Delivery, or Cost.
  • Defining equipment, tooling, and fixturing scope leading internal and/or external suppliers to ensure success on new and current product.
  • Addressing product and process design gaps through Engineering Change Notifications (ECNs), Deviations (DEVs), and Process Change Notifications (PCNs) to promote quality, continuous improvement, and countermeasures.
  • Defining, developing, and implementing critical quality controls using PFMEA thinking and verification techniques to support current and new product development (NPD).
  • Actively participating in the NPD process representing SMT as a core team member.
  • Researching, testing, and implementing the latest manufacturing technologies to improve safety, quality, delivery, and cost.

You will EXPLORE by:
  • Coaching or leading PDCA problem-solving to drive zone improvement in safety, quality, delivery, and cost.
  • Spearheading the development and implementation of Lean manufacturing strategies to improve efficiency and flow in the zone.
  • Coaching and leading process improvement teams on analysis and implementation while maintaining documentation to eliminate non-value-added processes.
  • Defining critical project criteria and plans to recommend process improvements with payback justifications.
  • Working with zones to support improvements from the top down; mentoring associates driving improvements from the bottom up.

You will PERFORM by:
  • Directing and assisting technicians with setup, modification, programming, and validation of process equipment and production lines to support current and new product.
  • Ensuring product and process designs promote a sustainable quality output within a safe working environment that meets delivery expectations.
  • Developing technical competency in areas of specialization.
  • Sharing knowledge and supporting other engineers and technicians on more complex problems or improvements.
  • Working with the entire team to standardize and share J.W.S. and industry best practices.

We offer competitive wages and the following great benefits:
  • Health, Dental, and Vision insurance
  • Short term & Long-term disability insurance
  • 401k with employer match
  • Paid time off, including Vacation, Sick & Personal Time, and 11 paid Holidays
  • Generous Profit-Sharing Plan
  • Tuition reimbursement & Scholarships
  • Development and Growth opportunities
  • Casual work environment for all associates
  • State-of-the-Art, temperature-controlled environment
  • And many more!

Equal Opportunity Employer/Protected Veterans/Individuals with Disabilities
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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