Upstream Process Engineer Jobs in Texas (NOW HIRING)

TITLE: Sr. Process Engineer II

POSITION OBJECTIVE: The Sr. Process Engineer II builds upon the foundational scope of the Level 1 role with an expanded mandate encompassing advanced automation engineering, full equipment lifecycle ownership (from installation through commissioning), and direct leadership of Level 1 engineers and technical staff. This role serves as the senior technical authority across four core manufacturing processes—blown film extrusion, in-line printing, bag forming (conversion), and product packaging (cartoning)—while driving automation strategy, overseeing capital installations, and ensuring compliance with environmental, OSHA, ASI, GMP, and CTPAT standards.

QUALIFICATIONS:

• Bachelor’s degree in engineering (Mechanical, Electrical, Chemical, or related discipline)
• 10+ years of experience in process control or manufacturing engineering, with at least 5 years in a leadership or supervisory capacity
• Advanced knowledge of process control systems: PID control loops, PLCs, SCADA, and DCS platforms
• Hands-on experience with PLC/HMI programming (e.g., Allen-Bradley, Siemens, Beckhoff) and industrial control system design
• Demonstrated experience with robotic systems integration in a manufacturing environment
• Experience designing and deploying automated packaging systems
• Proven ability to lead equipment installation and commissioning projects from kickoff through production handoff
• Experience conducting and managing Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT)
• Familiarity with utilities and facility infrastructure requirements for new equipment (electrical, pneumatics, compressed air, water)
• Demonstrated experience managing third-party vendors and contractors on-site during installations
• Strong proficiency in LEAN manufacturing, Six Sigma, or equivalent structured improvement frameworks
• Proven capital project management experience including budget ownership, vendor selection, and schedule management
• Excellent verbal and written communication skills with the ability to present to senior leadership
• Working knowledge of general manufacturing and business principles
• Ensure consistent, dependable attendance and demonstrate a willingness to accommodate non-standard work hours as necessary.
• Capable of effectively managing job-related stress and fostering productive workplace interactions.

AUTHORITY/DECISION MAKING

• Approve and implement process and automation changes that improve production efficiency, product quality, or cost-effectiveness
• Lead capital project planning and execution, including vendor selection, budget management, FAT/SAT, and project timelines
• Assign, prioritize, and oversee work across Level 1 engineers and technical staff based on business needs and project objectives
• Make final recommendations and decisions related to equipment upgrades, automation technology integration, and process control strategies
• Serve as the highest-level technical authority for root cause analysis, corrective action planning, and manufacturing-related escalations
• Approves installation plans, commissioning procedures, and equipment validation protocols
• Enforce and ensure compliance with safety, environmental, and regulatory standards across all process and automation areas
• Recommend and justify capital expenditures for automation equipment, technology, or facility infrastructure improvements
• Represent the engineering department in cross-functional meetings, project reviews, leadership presentations, and audits

JOB RESPONSIBILITIES:

Leadership & Team Development

• Lead, mentor, and directly supervise a team of engineers including Level 1 Sr. Process Engineers and technical professionals; conduct performance reviews and support career development
• Assign tasks, manage workloads, and build team capabilities across process engineering and automation disciplines
• Serve as escalation point and technical resource for engineering team problem-solving and decision-making

Automation Engineering

• Design, develop, and implement PLC/HMI programming solutions to automate and optimize manufacturing processes across blown film, printing, conversion, and packaging operations
• Lead the integration of robotic systems into production lines, including scoping, vendor coordination, installation, programming, and operator training
• Evaluate, specify, and deploy automated packaging systems; ensure seamless integration with upstream and downstream processes
• Process data analysis
• Develop and maintain automation standards, code libraries, and documentation to support scalability and ease of maintenance
• Partner with controls and maintenance teams to troubleshoot automation systems and resolve production-impacting issues

Equipment Installation & Commissioning

• Own the full lifecycle of capital equipment installations: scope development, contractor bidding, schedule management, installation oversight, commissioning, and handoff to production
• Develop and execute Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT) protocols to validate equipment performance against specifications
• Continuous improvement plans implementation
• Coordinate utilities and facility infrastructure requirements (electrical, pneumatics, compressed air, water, HVAC) for new equipment with facilities and outside contractors
• Manage on-site vendors and contractors during installation and commissioning activities; enforce safety protocols, quality standards, and schedule adherence
• Develop startup procedures, operator training materials, and equipment qualification documentation

Process Optimization & Continuous Improvement

• Design and maintain documentation for process improvements that enhance yield, uptime, and product quality across all four manufacturing process areas
• Lead cost-efficiency initiatives including formulation improvements, yield optimization, and downtime reduction programs
• Partner with Technical Specialists and Level 1 engineers on ongoing improvement initiatives and active manufacturing projects
• Investigate scrap events and process deviations; implement and verify corrective actions

Capital Project Management

• Develop and submit capital expenditure requests with clear business justification, ROI analysis, and technical rationale
• Manage multiple concurrent capital projects aligned with performance, budget, and schedule expectations
• Track and verify that completed projects meet expected performance targets; provide post-implementation reporting to management

Innovation & Technology Evaluation

• Evaluate emerging manufacturing technologies, automation platforms, and process innovations to increase throughput, reduce cost, and improve quality
• Lead proof-of-concept trials and technology pilots; develop recommendations for broader deployment

Compliance & Safety Leadership

• Actively lead Safety Committee participation; investigate incidents, implement corrective actions, and drive OSHA compliance across all process areas
• Ensure adherence to environmental standards, ASI guidelines, GMP requirements, and CTPAT security standards
• Enforce housekeeping protocols and regulatory compliance across all areas of engineering responsibility

Reporting & Collaboration

• Provide clear, consistent updates on project status, automation initiatives, and process improvement progress to engineering management and senior leadership
• Work cross-functionally with Sales, Marketing, Manufacturing, Maintenance, and IT to align engineering initiatives with business objectives
• Working with  Quality team on corrective actions
• Perform additional responsibilities as assigned by management