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Senior Process Development Engineer Jobs in Washington, DC

Peraton

Senior Process Engineer

Fort George G Meade, MD

$176K - $282K/yr

Responsibilities We are seeking a Senior Process Engineer to provide enterprise-focused engineering ... methodology development and evaluation, process engineering across all phases of acquisition ...

Peraton

Senior Process Engineer

Fort George G Meade, MD

$176K - $282K/yr

Responsibilities We are seeking a Senior Process Engineer to provide enterprise-focused engineering ... methodology development and evaluation, process engineering across all phases of acquisition ...

Peraton

Senior Process Engineer

Fort George G Meade, MD · On-site

$176K - $282K/yr

Responsibilities We are seeking a Senior Process Engineer to provide enterprise-focused engineering ... methodology development and evaluation, process engineering across all phases of acquisition ...

Peraton

Development Support Process Engineer

Linthicum, MD · On-site

$146K - $234K/yr

As a Development Support Process Engineer on our team, you will support a customer Program Management Office (PMO) overseeing a large multi-organizational agile software development project. You will ...

ERG

Senior Process Safety/Chemical Engineer

Fairfax, VA · On-site +1

$110K - $155K/yr

ERG is seeking a Senior Process Safety Engineer or Chemical Engineer to join our Risk Management Program (RMP) and Process Safety Management (PSM) compliance and enforcement team providing support to ...

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All JobsProcess Development Engineer JobsSenior Process Development Engineer JobsSenior Process Development Engineer Jobs in Washington, DC

Senior Process Development Engineer information

See Washington, DC salary details

$84.9K

$137.1K

$193K

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

As of Jul 16, 2026, the average yearly pay for senior process development engineer in Washington, DC is $137,125.00, according to ZipRecruiter salary data. Most workers in this role earn between $117,700.00 and $152,300.00 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.
What are popular job titles related to Senior Process Development Engineer jobs in Washington, DC? For Senior Process Development Engineer jobs in Washington, DC, the most frequently searched job titles are:
What job categories do people searching Senior Process Development Engineer jobs in Washington, DC look for? The top searched job categories for Senior Process Development Engineer jobs in Washington, DC are:
Senior Process Development Engineer jobs near you
Infographic showing various Senior Process Development Engineer job openings in Washington, DC as of July 2026, with employment types broken down into 1% As Needed, 79% Full Time, 18% Part Time, and 2% Contract. Highlights an 92% Physical, 2% Hybrid, and 6% Remote job distribution, with an average salary of $137,125 per year, or $65.9 per hour.

Sr. Process Engineer (Development Support)

Power3 Solutions

Linthicum, MD • On-site

$102K - $132K/yr

Full-time

Medical, Dental, Vision, Life, Retirement, PTO

Posted 29 days ago

Job description

We solve difficult business, IT, and analytic problems by addressing the whole problem - not just the symptoms - using interdisciplinary approaches that are both practical and innovative. We provide fresh alternatives to ordinary, mainstream consulting firms through small, highly skilled, and hand-picked teams that can meet clients' needs in any industry. Our broad interdisciplinary understanding allows us to provide the right solution, even if it is from outside the industry or traditionally defined problem space. We bring Public and Private, Civilian and Military expertise to every case.
We are hiring a Sr. Process Engineer (Development Support) to work in Linthicum Heights, MD. Position location is subject to change based on central MD client's needs.
Required: TS/SCI with a Polygraph
As a Development Support Process Engineer on our team, you will support a customer Program Management Office (PMO) overseeing a large multi-organizational agile software development project. You will provide process engineering support to plan and execute systems engineering and agile development processes.
Individual Capabilities/Experience Required:
  • Bachelor's degree in Computer Science, Information Systems, Engineering, Business, or Education from an accredited school or university is required.
  • Requires ten (10) years of experience with Process Improvement on programs and contracts of similar scope, type, and complexity. Experience is to include, within the past ten (10) years, five (5) years' experience in facilitation, training, methodology development and evaluation, process engineering across all phases of acquisition identifying best practices, change management, business management techniques, organizational development, activity and data modeling, or information system development methods and practices.
  • A high school diploma or GED plus 4 additional years of process engineering experience would also be acceptable in lieu of a qualifying college degree.
  • Experience planning and executing agile development projects.
  • Strong communication, interpersonal and mentoring skills
  • Position requires TS/SCI clearance with a polygraph that is less than 10 years old
Individual Capabilities/Experience Desired:
  • Strong oral, written and interpersonal communications skills.
  • Ability to work within a team setting to complete assigned tasks within expected schedule to complete.
  • Flexible/easily adaptable within a dynamic work environment that may require surge efforts.
  • Analysis of design and implementation alternatives, tradeoffs, and recommendations.
  • Analysis of functional, system, and non-functional requirements, data flows, and dependencies
  • Architecture experience (DoDAF).
  • Defining, developing, and documenting operational support concepts leading to development and implementation of requirements, specifications, and design plans.
  • SAFe/Agile methodology & Prior experience as a Product Owner/Scrum Master on an agile/scrum team
We have all the PERKS!
You are our most valuable resource - your ambition, your knowledge, your creativity. We offer an industry-leading set of benefits to supplement your normal salary compensation. We have you covered with flexible ways to balance work and home life, full health benefit premium coverage, and generous contributions toward your retirement.
  • Competitive health, dental, and vision plans with 100% paid premiums.
  • 401k: We contribute 6% even if you don't!
  • Time Off: 11 standard holidays, and 25 days of PTO
  • Career Development: Get career counseling and individualized career development plans, including education and training.
  • Employee referral bonuses for successful hires
We are an Equal Opportunity/Affirmative Action employer.
We provide equal employment opportunities to all employees and applicants for employment and prohibits discrimination and harassment of any type without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state or local laws.
This policy applies to all terms and conditions of employment, including recruiting, hiring, placement, promotion, termination, layoff, recall, transfer, leaves of absence, compensation and training.

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