Senior Process Engineer

Core Responsibilities

• Process Assessment & Current-State Analysis
• Assess existing end-to-end manufacturing processes, including:
• Manual, paper-based documentation
• Batch movement of product across multiple on-site manufacturing buildings
• Pre-, in-process, and post-operation safety inspections
• Required readings, sign-offs, and accountability steps at each phase
• Work directly with:
• Safety teams
• Quality personnel
• Machine operators and supervisors
• Operations and production leadership
• Observe and document how work is actually performed, not just how it is described in procedures
• Identify gaps, risks, inefficiencies, and compliance concerns in existing processes
• Stakeholder Engagement & Elicitation
• Elicit detailed process knowledge from non-technical stakeholders, including personnel who may be:
• Deep operational experience whose workflows are informal or not fully documented
• Skeptical or resistant to change
• Focused on safety, throughput, or compliance concerns
• Translate undocumented operational knowledge, experience-based workflows into clear, structured process documentation
• Build trust with operations teams by ensuring proposed changes:
• Improve safety
• Reduce burden
• Do not disrupt critical operations
• Compliance & Safety-Centered Process Design
• Ensure all process analysis and future-state designs:
• Preserve or enhance safety controls
• Support required compliance documentation and traceability
• Maintain clear accountability at every step of the process
• Understand and respect environments with:
• Strict procedural controls
• Required inspections and verifications
• Audit and review expectations
• Design processes that are defensible during internal and external review
• Digital Transformation & Future-State Design
• Lead the transition from paper-based processes to digital data capture, including:
• Tablet-based or workstation-based data entry
• Digital checklists, inspections, and sign-offs
• Structured capture of readings and measurements
• Define requirements for digital tools that:
• Reduce manual transcription
• Improve data accuracy and traceability
• Align with safety and compliance needs
• Ensure digital solutions reflect real operational workflows, not idealized models
• Documentation & Deliverables
• Produce clear, structured documentation, including:
• Current-state (“as-is”) process maps
• Gap and risk analyses
• Future-state (“to-be”) process definitions
• Requirements for digital workflows and data capture
• Clearly articulate:
• Why changes are necessary
• How safety and compliance are preserved or improved
• What operational impact is expected

Preferred Experience & Skills

• DoD manufacturing environment
• Energetics or ordnance environment
• Smart manufacturing environments
• Private 5g networks for data communication
• Functional understanding of Rockwell ControlLogix Allen Bradley PLCs, sensors (analog and digital), and HMIs
• Self-hosted (non-cloud) manufacturing systems, including 5G, IoT devices and hard-wired sensors.

Required Experience & Skills

• Proven experience as a Process Engineer in regulated, safety-critical manufacturing environments
• Strong background working with:
• Manual and paper-based compliance processes
• Batch manufacturing workflows
• Multi-building or campus-style operations
• Demonstrated ability to:
• Elicit requirements from non-technical stakeholders
• Navigate resistance to change
• Balance safety, compliance, and operational efficiency
• Experience supporting or leading digital transformation initiatives
• Excellent written and verbal communication skills
• Ability to operate independently in ambiguous environments
• Bachelor’s degree or equivalent military experience
• 5+ years in smart manufacturing
• Ability to document processes and requirements
• Ability to communicate well in writing and verbally with customers and stakeholder