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

Mastermold LLC

Paint Process Engineer

Johnson Creek, WI · On-site

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

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 ...

GEA Group

Process Engineer

Janesville, WI · On-site

As a Process Engineer, you would be responsible for supporting customers by optimizing GEA centrifugal equipment after delivery, supporting sales development, spearheading R&D efforts for new product ...

Family Fresh Pack Inc

Process Engineer

Monticello, WI · On-site

The Process Engineer is responsible for identifying and implementing manufacturing improvements that drive safety, quality, efficiency, yield, and profitability. This role partners closely with ...

Family Fresh Pack Inc

Process Engineer

Monticello, WI · On-site

The Process Engineer is responsible for identifying and implementing manufacturing improvements that drive safety, quality, efficiency, yield, and profitability. This role partners closely with ...

Illumina, Inc.

Process Engineer II

Madison, WI · On-site

You will drive process performance through process development and design, data-driven ... Desire to grow toward a Senior Engineer role by leading complex cross-functional projects from ...

Family Fresh Pack Inc

Process Engineer

Monticello, WI · On-site

The Process Engineer is responsible for identifying and implementing manufacturing improvements that drive safety, quality, efficiency, yield, and profitability. This role partners closely with ...

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 ...

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 ...

Fresh Pack Wisconsin

Process Engineer

Monticello, WI · On-site

$70K - $85K/yr

The Process Engineer is responsible for identifying and implementing manufacturing improvements that drive safety, quality, efficiency, yield, and profitability. This role partners closely with ...

Freshpack

Process Engineer

Monticello, WI · On-site

$70K - $85K/yr

The Process Engineer is responsible for identifying and implementing manufacturing improvements that drive safety, quality, efficiency, yield, and profitability. This role partners closely with ...

Kosmos

Process Engineer

Mcfarland, WI

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 ...

Family Fresh Pack Inc

Process Engineer

Monticello, WI · On-site

The Process Engineer is responsible for identifying and implementing manufacturing improvements that drive safety, quality, efficiency, yield, and profitability. This role partners closely with ...

GEA Group

Process Engineer

Janesville, WI

$95K - $105K/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 ...

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All JobsSr Process Engineer JobsSr Process Engineer Jobs in Madison, WI

Sr Process Engineer information

See Madison, WI salary details

$75.6K

$122.1K

$171.8K

How much do sr process engineer jobs pay per year?

As of Sep 1, 2026, the average yearly pay for sr process engineer in Madison, WI is $122,058.00, 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 a Sr Process Engineer?

Senior Process Engineers are experienced professionals responsible for designing, optimizing, and overseeing the processes used in manufacturing or production environments. They analyze workflows, troubleshoot process issues, and implement improvements to increase efficiency, reduce costs, and ensure product quality. Sr Process Engineers often lead teams, manage projects, and work closely with other departments such as quality assurance, maintenance, and operations. Their expertise is crucial in industries like chemicals, pharmaceuticals, oil and gas, and food processing. They typically hold a degree in engineering and have several years of experience in process engineering roles.

What are the key skills and qualifications needed to thrive as a Sr Process Engineer?

To thrive as a Sr Process Engineer, you need a solid background in chemical, mechanical, or industrial engineering, often with a bachelor's or master's degree and relevant industry experience. Familiarity with process simulation software (such as Aspen Plus or HYSYS), Six Sigma or Lean certifications, and knowledge of safety and regulatory standards are typically required. Strong problem-solving, project management, and communication skills help distinguish top performers in this role. These skills and qualifications are vital for optimizing processes, ensuring efficiency and safety, and driving continuous improvement in complex manufacturing environments.

How does a Sr Process Engineer typically collaborate with cross-functional teams to improve manufacturing efficiency?

Sr Process Engineers work closely with teams such as production, quality assurance, maintenance, and R&D to identify areas for process optimization. They often lead or participate in cross-functional meetings to gather data, analyze workflow bottlenecks, and implement solutions that enhance efficiency and product quality. Effective communication and project management skills are essential, as Sr Process Engineers must balance technical requirements with practical constraints while ensuring all stakeholders are aligned with proposed changes.

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

AspectSr Process EngineerProcess Engineer
QualificationsBachelor's degree in engineering, 5+ years experience, certifications like Six SigmaBachelor's degree in engineering or related field, 1-3 years experience
ResponsibilitiesLead process improvements, optimize manufacturing processes, mentor junior staffAssist in process development, data collection, support process optimization
Work EnvironmentManufacturing plants, industrial facilities, cross-functional teamsManufacturing settings, engineering teams, project-based tasks

The main difference between a Sr Process Engineer and a Process Engineer lies in experience, responsibility level, and scope of work. The Sr Process Engineer typically leads projects, mentors others, and has more advanced qualifications, while the Process Engineer supports and executes process improvements under supervision.

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 such as 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 industry standards. They also mentor junior engineers and collaborate with cross-functional teams to ensure smooth operations.

What are popular job titles related to Sr Process Engineer jobs in Madison, WI?

For Sr Process Engineer jobs in Madison, WI, the most frequently searched job titles are:

What job categories do people searching Sr Process Engineer jobs in Madison, WI look for?

The top searched job categories for Sr Process Engineer jobs in Madison, WI are:

What cities near Madison, WI are hiring for Sr Process Engineer jobs?

Cities near Madison, WI with the most Sr Process Engineer job openings:

Sr Process Engineer jobs near you
Infographic showing various Sr Process Engineer job openings in Madison, WI as of August 2026, with employment types broken down into 1% As Needed, 77% Full Time, 17% Part Time, 4% Contract, and 1% Nights. Highlights an 92% Physical, 2% Hybrid, and 6% Remote job distribution, with an average salary of $122,058 per year, or $58.7 per hour.

Paint Process Engineer

Johnson Creek, WI • On-site

Mastermold LLC
Plastics Product Manufacturing • 51 - 200 employees
Learn more about Mastermold LLCexternal

Full-time

Medical, Dental, Vision, Retirement, PTO

Re-posted 25 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.

Apply