ZipRecruiter

Log In

1

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

Mastermold LLC

Paint Process Engineer

Johnson Creek, WI · On-site

$90K - $108K/yr

Opportunities for growth into senior process engineering, project engineering, or leadership roles. * A visible impact: you'll see your process changes show up directly as better quality, less scrap ...

Mastermold LLC

Paint Process Engineer

Johnson Creek, WI · On-site

$90K - $108K/yr

Opportunities for growth into senior process engineering, project engineering, or leadership roles. * A visible impact: you'll see your process changes show up directly as better quality, less scrap ...

Sharpe Engineering

Process Engineer

Madison, WI · On-site

Sharpe Engineering & Equipment is seeking an experienced Process Engineer to support the design, development, and execution of sanitary process systems for the food & beverage industry. This hands-on ...

Sharpe Engineering

Process Engineer

Madison, WI · On-site

Sharpe Engineering & Equipment is seeking an experienced Process Engineer to support the design, development, and execution of sanitary process systems for the food & beverage industry. This hands-on ...

Automated Systems, Inc.

Process Engineer

Madison, WI · On-site

$65 - $85/hr

Process Engineer - API Manufacturing Remediation Location: Greater Madison, WI area - onsite Contract: 6+ month duration with potential for extensions Automated Systems, Inc. is seeking a Process ...

SHINE Technologies, LLC

Process Engineer

Janesville, WI · On-site

$90K - $132K/yr

SHINE Technologies is seeking a Process Engineer who will focus on systems in the Process Systems engineering group. This position will encompass ownership of different custom equipment in support of ...

SHINE Technologies LLC

Process Engineer

Janesville, WI · On-site

$90K - $132K/yr

Job Type Full-time Description SHINE Technologies is seeking a Process Engineer who will focus on systems in the Process Systems engineering group. This position will encompass ownership of different ...

Placon Corporation

Process Engineer

Madison, WI · On-site

$70K - $85K/yr

Process Engineer We're looking for a dependable Process Engineer who will be located in our Madison, WI facility that thrives in a fast‑paced GMP manufacturing environment and takes pride in ...

SHINE Technologies LLC

Process Engineer

Janesville, WI · On-site +1

$90K - $132K/yr

Description SHINE Technologies is seeking a Process Engineer who will focus on systems in the Process Systems engineering group. This position will encompass ownership of different custom equipment ...

Placon Corporation

Process Engineer

Madison, WI

$70K - $85K/yr

Process Engineer We're looking for a dependable Process Engineer who will be located in our Madison, WI facility that thrives in a fastpaced GMP manufacturing environment and takes pride in ...

Placon Corporation

Process Engineer

Madison, WI · On-site

$70K - $85K/yr

Process Engineer We're looking for a dependable Process Engineer who will be located in our Madison, WI facility that thrives in a fast-paced GMP manufacturing environment and takes pride in ...

Kosmos

Process Engineer

Mcfarland, WI

$110K - $140K/yr

Growing Manufacturing Company in Butte, Montana has a need for a Process Engineer. This is a direct hire role with a full benefits package and relocation. Prefer a B.S. in Engineering, and a minimum ...

GEA Group

Process Engineer

Janesville, WI

$95K - $115K/yr

The Process Engineer will be responsible for supporting testing, application development, troubling shooting, as well as, helping the service and parts business development in the (varies)portion of ...

GEA Group

Process Engineer

Janesville, WI · On-site

$95K - $115K/yr

The Process Engineer will be responsible for supporting testing, application development, troubling shooting, as well as, helping the service and parts business development in the (varies) portion of ...

Foth

Brewing Process Engineer

Madison, WI · Remote

Estimate process engineering hours and schedule for proposals * Oversee and QC engineering work of others (e.g., drawings, calculations, designs, etc.) * Support construction to include onsite and ...

Foth

Brewing Process Engineer

Madison, WI · On-site +1

$90K - $150K/yr

Estimate process engineering hours and schedule for proposals * Oversee and QC engineering work of others (e.g., drawings, calculations, designs, etc.) * Support construction to include onsite and ...

Foth

Brewing Process Engineer

Madison, WI · Remote

$90K - $150K/yr

Estimate process engineering hours and schedule for proposals * Oversee and QC engineering work of others (e.g., drawings, calculations, designs, etc.) * Support construction to include onsite and ...

Enerpac Tool Group Corp

Lead Process Engineer

Columbus, WI · On-site

$116K - $151K/yr

Serve as the primary owner for custom, engineered-to-order, and new product builds within Columbus operations * Lead execution for products that require non-standard processes, new capabilities, or ...

next page

Showing results 1-20

People also search for

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

Senior Process Engineer information

See Madison, WI salary details

$75.6K

$122K

$171.8K

How much do senior process engineer jobs pay per year?

As of Jun 11, 2026, the average yearly pay for senior process engineer in Madison, WI is $122,040.00, according to ZipRecruiter salary data. Most workers in this role earn between $104,800.00 and $135,500.00 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, and why are they important?

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 engineers make $300,000 a year?

Senior Process Engineers in industries such as oil and gas, chemical manufacturing, or aerospace can earn $300,000 or more annually, especially with extensive experience, specialized skills, and leadership roles. High compensation often includes bonuses, stock options, or other incentives, and requires advanced technical knowledge and certifications like Six Sigma or PMP.

What does a senior process engineer do?

A senior process engineer designs, develops, and optimizes manufacturing or industrial processes to improve efficiency, safety, and quality. They analyze data, troubleshoot issues, and implement process improvements, often using tools like process simulation software and adhering to safety and regulatory standards. They also mentor junior engineers and collaborate with cross-functional teams to ensure smooth operations.

What engineer makes $500,000 a year?

Senior Process Engineers in specialized industries such as oil and gas, chemical manufacturing, or aerospace can earn salaries approaching or exceeding $500,000 annually, especially with extensive experience, advanced certifications, and leadership roles. High compensation often includes bonuses, stock options, or profit sharing, and requires expertise in process optimization, safety standards, and industry-specific tools.

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 PMP.

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, WI? The most popular types of Process Engineer jobs in Madison, WI are:
What are popular job titles related to Senior Process Engineer jobs in Madison, WI? For Senior Process Engineer jobs in Madison, WI, the most frequently searched job titles are:
What job categories do people searching Senior Process Engineer jobs in Madison, WI look for? The top searched job categories for Senior Process Engineer jobs in Madison, WI are:
What cities near Madison, WI are hiring for Senior Process Engineer jobs? Cities near Madison, WI with the most Senior Process Engineer job openings:
Senior Process Engineer jobs near you
Paint Process Engineer

Paint Process Engineer

Mastermold LLC

Johnson Creek, WI • On-site

$90K - $108K/yr

Full-time

Medical, Dental, Vision, Retirement, PTO

Posted 3 days ago

Job description


We’re looking for Paint Process Engineers to own, stabilize, and improve our paint and coating processes. This role is less about “babysitting the line” and more about building robust processes that run right the first time, every time.

You’ll define standards, dial in parameters, reduce defects, and lead continuous improvement so production, quality, and maintenance have a repeatable, capable process to work with.


What You’ll Do

Process Engineering & Standardization

  • Develop, document, and maintain paint process standards (parameters, recipes, and work instructions) for existing and new products.

  • Define and optimize: gun settings, atomizing air, film build targets, flash/bake times, oven profiles, line speeds, and booth balance.

  • Build and maintain control plans, standardized work, and process check sheets for paint operations.

  • Use data (SPC, Pareto, capability studies) to identify variation and tighten up the process.

Defect Reduction & Root Cause Analysis

  • Lead structured problem-solving for paint defects (runs, sags, orange peel, dry spray, fisheyes, adhesion issues, color shifts, etc.).

  • Perform root cause analysis using tools like 5-Why, Fishbone, PDCA, and implement permanent corrective actions.

  • Partner with Quality to monitor scrap, rework, and first-pass yield, and drive projects to reduce defects.

Launches, Trials & Process Changes

  • Lead process development for new colors, coatings, or products—from lab trials to full production.

  • Plan and run process trials and DOE to evaluate new materials, equipment, and parameter changes.

  • Support PPAPs and customer approvals by preparing data, documentation, and sample runs as needed.

Cross-Functional Collaboration

  • Work closely with Production, Maintenance, Engineering, and Quality to ensure the paint process is understood, stable, and repeatable.

  • Train supervisors, leads, and operators on proper application techniques, defect recognition, and process controls.

  • Collaborate with Maintenance/Engineering on equipment upgrades, nozzle/robot changes, and oven/booth improvements.

Safety & Compliance

  • Ensure paint processes meet safety, environmental, and regulatory requirements.

  • Support safe storage, handling, and usage of paints, solvents, and chemicals used in the process.


What You Bring

Required

  • Bachelor’s degree in Chemical, Mechanical, Industrial, or Manufacturing Engineering
    OR equivalent hands-on experience in paint/coatings process engineering.

  • Direct experience with industrial painting or coating operations (automotive, heavy truck, agriculture, metal finishing, composites, etc.).

  • Strong process engineering mindset: comfortable with data, parameters, standardized work, and root cause analysis.

  • Ability to operate on the production floor, communicate with operators, and present clearly to leadership.

  • Proficiency with Excel and basic data analysis for reporting and process monitoring.

Preferred

  • Experience with powder coating, liquid paint, or gel coat systems, including pretreatment and curing ovens.

  • Familiarity with DFT measurement, gloss/color measurement, adhesion testing, and cure verification.

  • Experience with robotic application equipment and/or automated paint lines.

  • Exposure to Lean, Six Sigma, PFMEA, control plans, and CI projects in a manufacturing environment.


What We Offer

  • Competitive salary and performance-based bonus opportunity.

  • Comprehensive benefits package ([health/dental/vision/401(k)/etc.]).

  • Paid time off and holidays.

  • Opportunities for growth into senior process engineering, project engineering, or leadership roles.

  • A visible impact: you’ll see your process changes show up directly as better quality, less scrap, and smoother production.