Process Engineer

General Overview

This associate is responsible for technical ownership, support, and continuous improvement of energetic material manufacturing processes required to support production deliverables and new product development efforts. These processes range from dry‑blending of materials to complex chemical synthesis of initiating explosives. This is a hands‑on engineering role that works directly with production operators and cross‑functional partners to ensure assigned processes operate safely, reliably, efficiently, and in compliance with applicable Process Safety Management (PSM) and regulatory requirements.

The candidate will be responsible for teaming with Purchasing, R&D lab, Design Engineering, Manufacturing Engineering, Quality, Chemical Lab personnel, and Program Management.

• Lead and support Process Safety Management (PSM) activities for new and existing processes, including Process Hazard Analyses (PHA), Management of Change (MOC), Pre‑Startup Safety Reviews (PSSR), PSM audits, technical documentation, and implementation of corrective actions to assure personnel safety, environmental compliance, and safe operation.
• Maintain and improve existing energetic material processes to resolve safety concerns and enhance productivity, quality, reliability, and material performance.
• Participate in activities that provide required technical inputs for proposals.
• Support production manufacturing efforts including non‑conforming material disposition, powder qualification testing for release to production, assessment of raw, precursor, and finished materials, and active engagement with the Integrated Product Team (IPT) to resolve issues involving manufacturing processes and product testing related to energetic materials.
• Develop toward independent technical ownership of assigned energetic material process lines and associated equipment. Work hands‑on and shoulder‑to‑shoulder with production operators to ensure reliable supply of energetic material and provide guidance and technical leadership in resolving issues that impact safety, scrap, productivity, quality, equipment reliability, and product performance.
• Create, update, and maintain technical documentation, including manufacturing instructions, operating procedures, process specifications, engineering reports, process‑safety documentation, and other controlled documents.
• Apply statistical analysis and statistical process control to key process variables, including process capability, trend analysis, population/sample comparisons, and relationships between process variables to support process optimization and data‑driven decision making.
• Lead structured problem‑solving activities related to production anomalies, nonconforming lots, equipment issues, testing, customer complaints, or field returns using tools such as FMEA, Failure Analysis, Root Cause Analysis, and other appropriate methodologies.
• Support the Purchasing team to ensure the quality of raw materials, investigate supplier‑related issues, and identify alternative sources of raw materials.
• Research new manufacturing technologies that can be leveraged to replace aging processes or equipment, improve capability, and support future business needs. Working knowledge of PLC‑controlled manufacturing equipment is a plus.
• Support engineering project tasks including new equipment implementation, process changes, qualification activities, and conversion of lab‑scale synthesis into full‑scale manufacturing operations. Support scale‑up, ramp‑up, and introduction of new products and process families as business needs evolve.

• BS in Chemical Engineering strongly preferred. A BS in Chemistry or another closely related engineering or scientific discipline may be considered when combined with relevant process or manufacturing experience. MS preferred but not required.
• 3 or more years of relevant engineering experience preferred; exceptional candidates with less experience and strong technical depth may be considered. Experience in aerospace/defense, energetics, explosives, pyrotechnics, specialty chemical manufacturing, or another highly regulated…