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Senior Process Engineer Jobs in Madison, AL (NOW HIRING)

X-Bow Systems

Process Quality Engineer

Huntsville, AL · On-site

Process Quality Engineer Company: X-Bow Systems Location: Huntsville, AL (on-site) Position Type: Full-Time About the Role As a Process Quality Engineer, you will ensure that incoming and outgoing ...

Xbow

Process Quality Engineer

Huntsville, AL · On-site

Process Quality Engineer Company: X-Bow Systems Location: Huntsville, AL (on-site) Position Type: Full-Time --- About the Role As a Process Quality Engineer, you will ensure that incoming and ...

X-Bow Systems

Process Quality Engineer

Huntsville, AL · On-site

Process Quality EngineerCompany: X-Bow SystemsLocation: Huntsville, AL (on-site)Position Type: Full-Time---About the RoleAs a Process Quality Engineer, you will ensure that incoming and outgoing ...

KBR

Senior Systems Engineer (MBSE)

Huntsville, AL · On-site

$103K - $140K/yr

Senior Systems Engineer (MBSE) Job Summary KBR is seeking a Senior MBSE Systems Engineer to provide ... processes utilizing SysML/UML within Cameo Systems Modeler and related modeling environments.

KBR, Inc.

Senior Systems Engineer (MBSE)

Huntsville, AL · On-site

$103K - $140K/yr

Senior Systems Engineer (MBSE) Job Summary KBR is seeking a Senior MBSE Systems Engineer to provide ... processes utilizing SysML/UML within Cameo Systems Modeler and related modeling environments.

Plasma Processes LLC

Senior Propulsion Engineer

Huntsville, AL · On-site

$103K - $141K/yr

Rubicon Space Systems Senior Propulsion Engineer (Step II) Position Summary The Senior Propulsion ... Familiarity with requirements development and requirements flowdown processes. * Proven ability to ...

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All JobsProcess Engineer JobsSenior Process Engineer JobsSenior Process Engineer Jobs in Madison, AL

Senior Process Engineer information

See Madison, AL salary details

$67.2K

$108.5K

$152.8K

How much do senior process engineer jobs pay per year?

As of Aug 10, 2026, the average yearly pay for senior process engineer in Madison, AL is $108,517.00, according to ZipRecruiter salary data. Most workers in this role earn between $93,200.00 and $120,500.00 per year, depending on experience, location, and employer.

What is the difference between Senior Process Engineer vs Process Engineer?

AspectSenior Process EngineerProcess Engineer
QualificationsBachelor's or Master's in Engineering, often with 5+ years experienceBachelor's degree in Engineering or related field, typically 1-3 years experience
ResponsibilitiesLeading process improvements, mentoring, project managementSupporting process development, data analysis, assisting senior staff
Work EnvironmentDesign teams, manufacturing plants, R&D departmentsManufacturing facilities, engineering teams, operational support

Senior Process Engineers typically have more experience, leadership duties, and oversee complex projects, while Process Engineers focus on supporting process development and implementation. Both roles are essential in manufacturing and engineering industries, but the senior role involves greater responsibility and strategic planning.

What are the key skills and qualifications needed to thrive as a senior process engineer?

To thrive as a Senior Process Engineer, you need a strong background in chemical or process engineering, problem-solving skills, and typically a bachelor's or master's degree in a relevant field. Expertise in process simulation software (such as Aspen Plus or HYSYS), Six Sigma or Lean certifications, and familiarity with process control systems are highly valued. Outstanding analytical abilities, leadership, and effective communication set top performers apart in this role. These skills and qualifications are crucial for optimizing processes, ensuring safety and compliance, and leading teams to achieve operational excellence.

What does a senior process engineer do?

A Senior Process Engineer is responsible for designing, optimizing, and overseeing processes within manufacturing or production environments. They analyze workflows, troubleshoot issues, and implement improvements to increase efficiency, safety, and product quality. Senior Process Engineers often lead projects, mentor junior engineers, and collaborate with cross-functional teams to ensure operational excellence. Their expertise is vital in industries like chemicals, pharmaceuticals, oil and gas, and food processing.

How much does a senior process engineer earn?

A senior process engineer typically earns between $80,000 and $130,000 annually, depending on experience, industry, and location. They often have specialized skills in process optimization, project management, and may hold certifications like Six Sigma or PE licensure.

What are some common challenges senior process engineers face when working on cross-functional teams?

Senior Process Engineers often collaborate with professionals from various departments, such as operations, quality, and maintenance. A common challenge is aligning diverse priorities and communication styles to achieve shared project goals. Successfully managing these differences requires strong interpersonal and project management skills, as well as the ability to translate technical concepts for non-engineering colleagues. Regular meetings and clear documentation can help ensure everyone stays informed and engaged throughout the process.
What are the most commonly searched types of Process Engineer jobs in Madison, AL? The most popular types of Process Engineer jobs in Madison, AL are:
What are popular job titles related to Senior Process Engineer jobs in Madison, AL? For Senior Process Engineer jobs in Madison, AL, the most frequently searched job titles are:
What cities near Madison, AL are hiring for Senior Process Engineer jobs? Cities near Madison, AL with the most Senior Process Engineer job openings:
Senior Process Engineer jobs near you
Infographic showing various Senior Process Engineer job openings in Madison, AL as of August 2026, with employment types broken down into 1% As Needed, 76% Full Time, 19% Part Time, 3% Contract, and 1% Nights. Highlights an 92% Physical, 2% Hybrid, and 6% Remote job distribution, with an average salary of $108,517 per year, or $52.2 per hour.

R&T Polymerization Process Engineer

Hexcel Corporation

Decatur, AL • On-site

Full-time

Re-posted 8 days ago

Hexcel rating

7.5

Company rating: 7.5 out of 10

Based on 19 frontline employees who took The Breakroom Quiz

Job description

Ready to Shape the Future of Advanced Materials?

Are you a polymerization expert looking to make a real impact in aerospace, defense, and clean energy? Do you thrive at the intersection of innovation and industrial scale-up? If you're ready to lead transformative projects that push the boundaries of composite materials, this is your boarding pass to a career that matters.

Hexcel is seeking a R&T Polymerization Process Engineer to join our team in Decatur, AL.

Why This Role Matters

This isn’t just another engineering job. You’ll be driving the development of scalable, sustainable polymerization processes that fuel the next generation of aircraft, wind turbines, and space exploration. Your work will directly influence how high-performance materials are made and used across industries that shape our world.
 

At Hexcel, your ideas won’t sit on a shelf—they’ll be piloted, scaled, and launched into production.
 

What You Will Do

  • Lead polymerization process from lab to pilot to full-scale production, ensuring safety, compliance, and performance.
  • Develop scalable manufacturing solutions for PAN polymer with a focus on sustainability and efficiency.
  • Accelerate Time-to-Market: Streamline technology development to bring new products to life faster.
  • Work with cross-functional teams to integrate innovations into production and drive continuous improvement.
  • Apply advanced polymerization methods and stay current with technical literature to fuel ongoing development.
     

Your Boarding Pass

To thrive in this role, you’ll need:

  • Advanced degree in Chemical Engineering, Polymer Science, or related field. Ph.D. preferred.
  • 5+ years in chemical process development, with direct experience in industrial solution polymerization.
  • Expertise in polymer chemistry, structure-property relationships, and scaling R&D to production.
  • Hands-on experience with pilot equipment and a collaborative approach to problem-solving.
  • Strong team leadership and stakeholder engagement skills.
  • Familiarity with Process Safety Management environments.
     

Why Decatur, AL?

It all starts here. Decatur is more than just a manufacturing site—it’s a community of innovators that sets the stage for precision downstream processes at other Hexcel sites. Nestled along the Tennessee River, Decatur offers a blend of Southern charm, outdoor adventure, and a growing tech scene. With a lower cost of living and access to nature, it’s a place where you can build both a career and a life. Relocation assistance available.

About Hexcel

With our strong investment in research and development and our culture of continuous improvement, Hexcel is the industry leader in the manufacturing of advanced composite materials, including carbon fiber, woven reinforcements, resins, prepregs, honeycombs, and additive manufactured parts. We invite you to join the Hexcel team at various manufacturing sites, sales offices, and R&T centers around the globe. Become a part of the “strength within.”

Eligible candidates must be a:  U.S. citizen, U.S. national, person lawfully admitted for permanent residence, temporary resident under sections 210(a) or 245(A) of the Immigration and Nationality Act, person admitted in refugee status, or person granted asylum. Hexcel (NYSE: HXL) is a global leader in advanced composites technology, a leading producer of carbon fiber, and the world leader in honeycomb manufacturing for the commercial aerospace industry.

Hexcel is an Equal Opportunity Employer of Minorities/Females/Protected Veterans/Individuals with Disabilities.  All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, age, national origin, physical or mental disability, status as a protected veteran, or any other protected class.

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