Senior Process Development Engineer

Job DetailsJob Location: Chicago CIC - Chicago, IL 60607Salary Range: $102,994.61 - $169,225.50 SalaryThe Senior Process Development Engineer is responsible for leading complex process research and development activities to enable the successful scale-up, optimization, and industrialization of new and existing products. The role focuses on developing robust manufacturing processes, applying scale-up laws, and building process models for existing or new unit operations. The position combines experimental work, process modeling and simulation, and technical leadership to support business objectives while ensuring compliance with safety, quality, and regulatory standards.

 

Key Responsibilities

Leadership and Direction


Communicate and execute local action plans aligned with the function’s strategy and the broader organization’s mission and vision.
Demonstrate strong leadership behaviors, including effective communication, accountability, and proactive problem solving.
Provide technical leadership within process R&D programs and across cross-functional teams.


 

Process Research and Development


Lead and manage significant elements of the organization’s process R&D program, with accountability for process development, scale-up, and technology transfer.
Develop new manufacturing processes for new products, with a strong emphasis on process design, robustness, and scalability.
Identify new process opportunities and conduct innovative experimental and modeling work to translate laboratory concepts into manufacturable solutions.


 

Process Experiments and Scale-Up


Propose, design, prioritize, and safely execute laboratory, pilot-scale, and scale-up experiments.
Apply fundamental engineering principles and scale-up laws to guide process design and scale-up decisions.
Interpret experimental data and integrate scientific and engineering principles into process development projects.


 

Process Modeling, Data, and Analytics


Develop and apply process models for existing and new unit operations using appropriate modeling, simulation, and statistical tools.
Use data analysis, statistical methods, and modeling to evaluate hypotheses, predict performance, and optimize processes.
Define and lead execution of data and analytics reporting strategies, ensuring results are communicated in a clear, actionable manner to stakeholders.


 

Methodologies, Tools, and Continuous Improvement


Identify gaps or shortcomings in current process development methodologies, tools, and workflows.
Propose, implement, and standardize improved process development, modeling, and scale-up practices.
Develop and validate new test methods and process characterization techniques as required.


 

Communication and Collaboration


Write clear technical reports documenting process development work, experimental results, and modeling outcomes.
Present technical findings to R&D, operations, and management, and communicate effectively across functions and sites.
Engage with external partners, suppliers, customers, and development collaborators as needed to support process development goals.


 

Innovation and Intellectual Property


Contribute to innovation through the development of novel processes, unit operations, and modeling approaches.
Understand intellectual property related to process and manufacturing technologies and support invention disclosures, patent analyses, and interactions with patent counsel.
Maintain awareness of external technological advances and competitive process technologies.


 

Project and Portfolio Management


Plan and deliver process development projects or workstreams using appropriate project management methodologies.
Balance technical depth with project execution to ensure milestones are achieved on time and within scope.
Act as a process R&D representative on strategic and cross-functional business teams.


 

People Development


Provide technical guidance, coaching, and mentoring to junior engineers, scientists, and technicians.
Support capability building within the team through training, knowledge sharing, and best-practice development.


 

Safety, Quality, and Compliance


Comply with and actively support R&D and laboratory safety programs.
Assume responsibility for assigned lab, pilot, or process areas, including safety, quality, and maintenance standards.


 

 

Required Skills and Competencies

 


Advanced knowledge of process engineering principles, including scale-up laws and unit operations.
Strong background in process modeling, simulation, and data analysis.
Proficiency with analytical, statistical, and scientific software used for modeling and process development.
Ability to manage complexity, optimize work processes, and apply continuous improvement principles.
Strong communication, collaboration, and stakeholder manageme