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Senior Process Safety Engineer Jobs in Illinois (NOW HIRING)

Burgess Norton Mfg Co

Senior Process Engineer

Geneva, IL · On-site

$123K - $157K/yr

Amsted Automotive, Burgess-Norton division is seeking an experienced Senior Process Engineer to support manufacturing and process engineering initiatives across our global operations. This role is ...

Amsted Automotive Group

Senior Process Engineer

Geneva, IL · On-site

$123K - $157K/yr

Amsted Automotive, Burgess-Norton division is seeking an experienced Senior Process Engineer to support manufacturing and process engineering initiatives across our global operations. This role is ...

Ingredion

Senior Process Engineer

Bedford Park, IL · On-site

$102K - $136K/yr

... safety, and cost performance. This role plays a critical part in scaling best practices and ... As a Senior Process Engineer, you will be responsible for designing, optimizing, and standardizing ...

Ingredion Incorporated

$113K - $146K/yr

... safety, and cost performance. This role plays a critical part in scaling best practices and ... As a Senior Process Engineer , you will be responsible for designing, optimizing, and standardizing ...

Shure

Senior Process Engineer

Niles, IL · Hybrid

$104K - $135K/yr

As our Senior Process Engineer , you'll play a key role in bringing innovative products from ... improve worker safety, and/or improve manufacturing effects on the environment for existing ...

Shure

Senior Process Engineer

Niles, IL · Hybrid

$104K - $135K/yr

As our Senior Process Engineer , you'll play a key role in bringing innovative products from ... improve worker safety, and/or improve manufacturing effects on the environment for existing ...

Shure

Senior Process Engineer

Niles, IL · On-site

$104K - $135K/yr

As our Senior Process Engineer , you'll play a key role in bringing innovative products from ... improve worker safety, and/or improve manufacturing effects on the environment for existing ...

Shure

Senior Process Engineer

Niles, IL · Hybrid

$104K - $135K/yr

As our Senior Process Engineer , you'll play a key role in bringing innovative products from ... improve worker safety, and/or improve manufacturing effects on the environment for existing ...

Zachry Group

Sr Engineer Process

Downers Grove, IL · On-site

$148K - $211K/yr

Zachry Group is currently accepting applications for a Senior Process Engineer in our Downers Grove ... with safety and environmental regulations. Experience in PFD and P&ID development, and ...

Zachry Group

Sr Engineer Process

Downers Grove, IL · On-site

$148K - $211K/yr

Zachry Group is currently accepting applications for a Senior Process Engineer in our Downers Grove ... with safety and environmental regulations. • Estimate resource requirements of new project ...

Paper Converting Machine

Sr. Process Engineer

Oak Brook, IL · On-site

$105K - $135K/yr

When you join Design Group as a Sr. Process Engineer, you are joining a team that will challenge you and position you for growth. In this role, you will work with a team of industry experts to help ...

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All JobsProcess Safety Engineer JobsSenior Process Safety Engineer JobsSenior Process Safety Engineer Jobs in Illinois

Senior Process Safety Engineer information

See Illinois salary details

$72.7K

$117.4K

$165.2K

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

As of Sep 3, 2026, the average yearly pay for senior process safety engineer in Illinois is $117,364.00, according to ZipRecruiter salary data. Most workers in this role earn between $100,800.00 and $130,300.00 per year, depending on experience, location, and employer.

What does a senior process safety engineer do?

A Senior Process Safety Engineer is responsible for ensuring that industrial processes, especially those involving hazardous materials, are designed and operated safely to prevent accidents and minimize risks. They analyze operations, conduct safety assessments, and implement systems to comply with safety regulations. Additionally, they lead incident investigations, develop safety procedures, and provide technical guidance to engineering teams to promote a strong safety culture within the organization.

What are the key skills and qualifications needed to thrive as a senior process safety engineer, and why are they important?

To thrive as a Senior Process Safety Engineer, you need a solid background in chemical or process engineering, in-depth knowledge of process safety management (PSM), and typically a bachelor's degree in engineering with relevant certifications like CSP or CCPSC. Familiarity with process hazard analysis (PHA) tools, safety lifecycle software (such as PHA-Pro or BowTieXP), and regulatory standards (OSHA, API) is crucial. Strong analytical thinking, leadership, and effective communication skills help you guide multidisciplinary teams and convey complex safety issues clearly. These competencies are vital to ensure operational safety, regulatory compliance, and the prevention of major incidents in high-risk industrial environments.

What are the main challenges a senior process safety engineer faces when implementing new safety protocols across multiple facilities?

A Senior Process Safety Engineer often encounters challenges such as ensuring consistent application of safety standards across diverse sites, gaining buy-in from cross-functional teams, and adapting protocols to facility-specific hazards. Additionally, balancing regulatory compliance with operational efficiency requires strong communication and project management skills. Successfully addressing these challenges usually involves close collaboration with site managers, operations teams, and regulatory bodies, as well as ongoing training and audits to maintain high safety standards.

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

AspectSenior Process Safety EngineerProcess Safety Engineer
CertificationsTypically holds API, NEBOSH, or equivalent certificationsOften requires similar certifications, but less experience needed
Work EnvironmentLeads safety projects, mentors junior staff, and manages complex risk assessmentsSupports safety initiatives, conducts hazard analyses, and assists in safety documentation
Employer & Industry UsageCommon in oil & gas, chemical, and refining industriesUsed across similar industries, often as entry to mid-level role

The main difference between a Senior Process Safety Engineer and a Process Safety Engineer lies in experience, leadership responsibilities, and project scope. Senior professionals typically lead safety initiatives and mentor others, while Process Safety Engineers focus on supporting safety tasks and analysis. Both roles are vital for maintaining safety standards in high-risk industries.

What are the most commonly searched types of Process Safety Engineer jobs in Illinois?

The most popular types of Process Safety Engineer jobs in Illinois are:

What are popular job titles related to Senior Process Safety Engineer jobs in Illinois?

For Senior Process Safety Engineer jobs in Illinois, the most frequently searched job titles are:

What job categories do people searching Senior Process Safety Engineer jobs in Illinois look for?

The top searched job categories for Senior Process Safety Engineer jobs in Illinois are:

What cities in Illinois are hiring for Senior Process Safety Engineer jobs?

Cities in Illinois with the most Senior Process Safety Engineer job openings:

Senior Process Safety Engineer jobs near you
Infographic showing various Senior Process Safety Engineer job openings in Illinois as of August 2026, with employment types broken down into 1% As Needed, 63% Full Time, 34% Part Time, 1% Contract, and 1% Nights. Highlights an 99% Physical, and 1% Remote job distribution, with an average salary of $117,364 per year, or $56.4 per hour.

Senior Process Engineer

Burgess Norton Mfg Co

Geneva, IL • On-site

$123K - $157K/yr

Full-time

Medical, Dental, Vision, Retirement, PTO

Re-posted 14 days ago

Job description

Amsted Automotive, Burgess-Norton division is seeking an experienced Senior Process Engineer to support manufacturing and process engineering initiatives across our global operations. This role is responsible for driving process improvements, supporting new program launches, and working with cross-functional teams to ensure consistent, efficient manufacturing processes across multiple facilities.

Duties and Responsibilities

  • Manage Manufacturing / Process Engineering projects for Cold Form & Finishing facilities and support global grinding processes for parts production (including manufacturing location decisions, manufacturing capability analysis and development).
  • Drive consistency of grinding operations across all piston pin manufacturing plants (in Geneva, IL, Monterrey, MX, Turin, IT) by developing grinding wheel standards, coolant formulas, and blade designs.
  • Build end-of-line inspection standards for global grinding operations by exploring opportunities to add automation along with improved training and standards for human inspectors.
  • Support the Program Management launch process for all facilities as it relates to process capability and capacity.
  • Direct involvement in the sharing of “best practices” for process engineering as it pertains to meeting customer specifications.
  • Manage capital purchases of new equipment from initiation through runoff and start-up with global manufacturing locations.
  • Provide continuous assessment of the current state of production equipment to provide capacity and capability assessment to management staff.
  • Work closely with plant management to drive execution of customer requirements and growth initiatives in their respective plants.
  • Manage continuous improvement projects with manufacturing facilities, providing support to local teams, and outsourcing as needed.
  • Mentor site engineering teams to ensure process consistency and effectiveness of company continuous improvement programs. 
  • Domestic travel in Michigan and International travel to Mexico and Italy required up to 25% of the time.

Qualifications

Education

  • Bachelor’s degree or foreign equivalent in Mechanical Engineering, Industrial Engineering, or Manufacturing Engineering, or a closely related field (will accept single degree determined to be equivalent by a qualified evaluation service)

Experience

  • At least 5 years of experience working in an automotive (OEM or supplier) environment including:
    • 5 years of experience working with centerless grinding as a metal production process,
    • 5 years experience working with Statistical Process Control techniques,
    • 5 years experience working with analytical problem solving tools, AND
    • 2 years experience working with international manufacturing teams.

Travel

  • Domestic travel in Michigan and International travel to Mexico and Italy required up to 25% of the time.

Wage Range 

  • $123,635 - $157,470 per year

Benefits 

  • Medical, dental, vision, 401(k), PTO, ESOP