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Senior Process Development Engineer Jobs in Washington, DC

Govcio LLC

Senior Process Analyst

Alexandria, VA · On-site

$105K - $130K/yr

Oversee the development, documentation, and maintenance of rigorous IT-to-business roadmaps to ... and process governance models. * Experience collaborating with senior leadership and cross ...

Software Technology Inc

Mid/Senior SDET

Rockville, MD · On-site

$112K - $146K/yr

Mid-Senior Software Development Engineer In Test Location: Rockville, MD Role Overview: Apex Systems has an immediate opening for a mid-senior Software Development Engineer In Test (SDET). The ...

Cooley LLP

Senior Legal Process Engineer

Reston, VA

$108K - $139K/yr

Senior Legal Process Engineer Cooley is seeking a Senior Legal Process Engineer to join the ... Familiarity with product development methodologies (Agile, Lean, etc.) and experience working ...

Cooley

Senior Legal Process Engineer

Washington, DC

$117K - $152K/yr

Senior Legal Process Engineer Cooley is seeking a Senior Legal Process Engineer to join the ... Familiarity with product development methodologies (Agile, Lean, etc.) and experience working ...

Cooley

Senior Legal Process Engineer

Reston, VA

$108K - $139K/yr

Senior Legal Process Engineer Cooley is seeking a Senior Legal Process Engineer to join the ... Familiarity with product development methodologies (Agile, Lean, etc.) and experience working ...

Cooley LLP

Senior Legal Process Engineer

Washington, DC

$117K - $152K/yr

Senior Legal Process Engineer Cooley is seeking a Senior Legal Process Engineer to join the ... Familiarity with product development methodologies (Agile, Lean, etc.) and experience working ...

Ageatia Global Solutions

Engineer, Software Sr SDET

Reston, VA · On-site

$115K - $149K/yr

Kindly let me know your interest by forwarding your updated resume, rate and contact details for further process. Job Title: Senior Software Engineer/SDET Location: Reston, VA Duration: 6 Months ...

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All 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 Jun 26, 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.

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 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

Senior Process Automation Engineer - Siemens Exp Required

GEA Group

Columbia, MD • On-site

$104K - $135K/yr

Full-time

Medical, Dental, Vision, Retirement, PTO

Posted 7 hours ago

Job description

GEA Group, founded in Germany in 1881, is a global leader in engineering solutions, serving industries such as food and beverage, pharma, dairy, and more. With over 18,000 employees worldwide and a strong U.S. presence since 1929, GEA combines the heritage of a well-established company with the innovation of a forward-thinking industry leader. At GEA, we're not just building equipment, we're building lasting careers with an average employee tenure range from 5 to over 11+ years, reflecting the strong culture, growth opportunities, and support we provide.
Responsibilities / Tasks
  • Start strong - Medical, dental, and vision coverage begins on your first day
  • Recharge and refresh - Enjoy 12 paid holidays, including a flexible floating holiday, and 136 hours of PTO to relax or explore
  • Invest in your future - A 7% 401(k) employer match helps grow your retirement savings faster
  • Keep learning - Take advantage of tuition reimbursement to further your education or skillset
  • Live well - Our wellness incentive program rewards healthy habits
  • Get support when you need it - Access to a confidential Employee Assistance Program for personal or professional guidance
  • Save smart - Flexible Health Savings and Spending Accounts to manage out-of-pocket expenses

GEA Group, located in Columbia, MD, is searching for a Senior Process Automation Engineer to join our Team!
GEA's Process Engineering Team is a dynamic, technologically advanced and global export-oriented organization, focused on the design, development and manufacturing of complex process equipment for the production of pharmaceutical oral solid dosage (OSD) forms.
Responsibilities:
  • Works effectively with the GEA Core Technology Center (CTC) for the OSD system design in alignment with the Pharma North America (NAM) stakeholders to design, develop, install, and commission and supports OSD software and systems for the NAM Pharma market through service demands
  • Works closely with the software engineering group within our CTC, located in Wommelgem, Belgium for training, projects, software design related for customer projects and field service-related activities within NAM
  • Develops customer specific software using standard engineered modules as well as software design best practices
  • Participates in project team development, meetings and regularly reports status for software engineering development
  • Manages, estimates and reports on times for projects as well as utilization, billing and costing of projects
  • Maintains continuous improvement mindset and openly discusses improvements with the automation standardization leadership team at the CTC and in NAM team
  • Conducts review meetings with the customers explaining software architecture, optimization and updates
  • Executes software develop activities for global customers for assigned projects
  • Participates in review meetings with other GEA departments outside Wommelgem to standardize the automation processes, development and customization approach
  • Develop SOPs and work instructions with the CTCs for designated Field Service Activities to support service resources and their ability to effectively handle high level software updates, diagnostics and onsite troubleshooting
  • Interpret part and assembly drawings, electrical schematics, P&ID's, System General Arrangements, and other types of technical drawings and specifications for the information required for complete system troubleshooting, modifications and enhancements
  • Review information received from GEA CTC's and process it into locally useable technical documents and work instructions for field service and customer support responsibilities
  • Investigate start up, delivery problems and customer complaints. Produce reports and communications as appropriate to resolve problems and assist with process improvement efforts
  • Support colleagues when they are in the field at customer sites (e.g. Field Service Technicians and Engineers), by providing or arranging for the provision of information, documents, parts, or any other assistance as required
  • Follow up with customers and affiliates as required to clarify questions and to obtain the information required to answer them if the information is not readily available
  • Assist with the creation and maintenance of NAM iBase records.
  • Follows important procedural tasks such as time sheets, vacation requests, and expense reports and follows GEA policies including Travel and the Health and Safety handbook.
  • Contribute to team effort by working the necessary hours, including reasonable overtime, to satisfy customer requests.
  • Complete all tasks as may be assigned with high quality, and all documented for further improvements, audits, or records.
  • Be the "Face of GEA"; good people skills and professional behavior are required as well as the alignment to the GEA values
  • In the spirit of, and in concert with, the concepts of continuous improvement, the person in this role must think about the way tasks are performed and work collaboratively with management and colleagues to streamline and improve our Ways of Working
  • Provides feedback to the CTC's and NAM colleagues with constructive and informative communications that foster collaboration and shared understandings as well as corrective actions as part of the requirements of this important role

Your Profile / Qualifications
  • Bachelor's degree in Electrical Engineering with Software focus, plus 5+ years of related experience as software/controls engineer in process industry (food, beverage, pharma or other related,) OR Master's Degree in Automation/Controls engineering.
  • Knowledge and experience programming most of the following systems: Siemens PLC's (S7 1500) and TIA Portal, Siemens WinCC SCADA systems, Scripting (VBS,), Rockwell solutions, MS SQL server
  • Able to read mechanical drawings. Knowledge or Good Automation Manufacturing Practice (GAMP)
  • Profound Customer Care expertise and Service oriented personality are required
  • Analytical capabilities, problem-solving skills and ability to think and offer solutions to customer issues quickly
  • Excellent written and verbal communication skills
  • Strong Customer / market orientation with commitment to fast customer responses
  • Continuously looking for improvements to match requirements from pharmaceutical companies with scheduled hours per project for controls activities.
  • Must be proficient with MS Office applications, especially Word, Excel and Visio
  • Must be prepared to travel up to 60%
  • Extensive initial training period in Belgium for a 1-2-month period

The typical base pay range for this position at the start of employment is expected to be between $100,000.00 - $130,000.00 per year. GEA Group has different base pay ranges for different work locations within the United States.
The pay range is not a guarantee of compensation or salary. The estimated range is the budgeted amount for the position. Final offers are based on various factors, including skill set, experience, location, qualifications, and other job-related reasons. You may be eligible for additional rewards, such as discretionary bonus (based on eligibility) and/or equity awards.
Please note: This position is based in the United States and does not offer visa or work sponsorship. Applicants must be authorized to work in the U.S. without current or future sponsorship.
GEA is an equal opportunity employer. Applicants will therefore receive consideration for employment without regard to age, sex, race, color, religion, world view, national origin, genetics, disability, gender identity, marital status, sexual orientation, veteran status or any other protected characteristic required by applicable law. Applicants with disabilities are welcome and will be given special consideration if they are equally qualified.
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