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Senior Process Development Engineer Jobs (NOW HIRING)

Meissner Filtration Products

$106.10K - $137.20K/yr

Are you a highly skilled and motivated Senior R&D Process Development Engineer passionate about bioprocessing and separation technologies? Join our leading research and development team to lead end ...

Teleflex

Process Development Engineer

Trenton, GA

... process development and design to meet customer product requirements. Provide engineering support of products as they advance into production. Lead major projects involving capital improvement ...

Nokia

Process Development Engineer

Allentown, PA · On-site

The person should have hands-on experience with process development and be well versed in mechanical engineering or materials science as well as with automated equipment in a high-volume ...

Nokia

Process Development Engineer

Allentown, PA

The person should have hands-on experience with process development and be well versed in mechanical engineering or materials science as well as with automated equipment in a high-volume ...

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$75K

$121.1K

$170.5K

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

As of May 31, 2026, the average yearly pay for senior process development engineer in the United States is $121,116.00, according to ZipRecruiter salary data. Most workers in this role earn between $104,000.00 and $134,500.00 per year, depending on experience, location, and employer.

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 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 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 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 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 cities are hiring for Senior Process Development Engineer jobs? Cities with the most Senior Process Development Engineer job openings:
What states have the most Senior Process Development Engineer jobs? States with the most job openings for Senior Process Development Engineer jobs include:
Senior Process Development Engineer jobs near you
Infographic showing various Senior Process Development Engineer job openings in the United States as of May 2026, with employment types broken down into 88% Full Time, 9% Part Time, and 3% Contract. Highlights an 91% Physical, 2% Hybrid, and 7% Remote job distribution, with an average salary of $121,116 per year, or $58.2 per hour.

Process Development Engineer

Mirus Consulting Group

Dorado, PR

Other

Posted 16 days ago

Job description

mirus Consulting Group is a local company based in Humacao, Puerto Rico that provides computer system validation and information technology consulting services to pharmaceutical companies and other organizations across the Island and parts of the United States. Its services include the assessment and validation of automation equipment, network infrastructures and business processes, as well as the project management involved.
Role Summary
The Process Development Engineer supports the development, validation, and implementation of new manufacturing processes. The role involves equipment and process validation, documentation generation, process optimization, and cross-functional technical collaboration.
Key Responsibilities

  • Support IQ/OQ/PQ and process performance qualification activities; develop validation protocols, reports, and master validation plans.
  • Design and develop inprocess and receiving inspection systems for new components and processes.
  • Generate equipment documentation (evaluations, PM/calibration procedures) and manufacturing instructions.
  • Manage process development projects from concept through implementation; collaborating with cross-functional teams.
  • Apply DOE, PFMEA, and risk analysis to characterize, optimize, and improve manufacturing processes.
  • Work with technologies such as laser welding, heat bonding, injection molding, vision systems, and automation (PLC/servo/pneumatics/sensors).
Process Characterization & Reporting Activities
  • Evaluate current manufacturing process flows and identify gaps and improvement opportunities.
  • Analyze product requirements to ensure alignment with manufacturing capabilities.
  • Assess manufacturability and scalability of processes.
  • Review historical process data, including yield trends, scrap rates, and process capability.
  • Perform time studies and cycle time analysis to optimize efficiency.
  • Execute Design of Experiments (DOE) studies for process characterization and optimization.
  • Develop and maintain PFMEA documentation.
  • Conduct engineering assessments to support decision-making and technical justification.
  • Create and maintain process flow diagrams.
  • Develop automation concepts to improve process capability and efficiency.
  • Perform feasibility studies for new processes, technologies, or equipment.
  • Conduct risk assessments to identify and mitigate process risks.
  • Define validation strategies, including preliminary validation approaches for new and existing processes.
Experience Requirements
  • 5-7+ years in manufacturing engineering or quality engineering within an FDAregulated environment (medical devices, pharma, diagnostics, biotech).
  • Strong working knowledge of 21 CFR Part 820, GMP, and ISO 13485.
  • Electrical and mechanical engineering background applied to automated manufacturing systems.
  • Experience with automation/controls, tooling, fixtures, test method development, and equipment qualification.
  • Proficiency in DOE, FMEA, CAPA, and rootcause investigation.
  • Experience supporting new product introductions and process scaleup.

This Company is an equal employment opportunity employer. We adhere to a policy of making employment decisions without regard to race, color, religion, sex, sexual orientation, national origin, citizenship, age or disability. We assure you that your opportunity for employment with this Company depends solely on your qualifications.

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