Manufacturing Process Engineer

Overview

Aspen is a technology leader in sustainability and electrification solutions. We develop aerogel technology that enables our customers and partners to achieve resource efficiency, e‑mobility, and clean energy goals. Our Pyro Thin® products address thermal runaway in the electric vehicle market, and our Cryogel® and Pyrogel® products serve the world’s largest energy infrastructure companies. Aspen is headquartered in Northborough, Mass.

Aspen partners with world‑class industry leaders to extend our Aerogel Technology Platform® into high‑value markets.

Our core values reflect how we work with each other, our customers, suppliers, and communities. They guide our decisions and inspire us to make a meaningful impact within Aspen and in all our relationships.

• We Do the Right Thing
• We are Problem Solvers
• We are Allies
• We Drive Forward

Reporting to the Sr. Manager, Operations, the Manufacturing Process Engineer supports safe, reliable, and efficient manufacturing operations in a Process Safety Management (PSM) covered facility. The role partners closely with operations, maintenance, and EHS teams to optimize process performance, maintain regulatory compliance, and implement continuous improvement initiatives.

• Support compliance with OSHA Process Safety Management (29 CFR ) and other applicable regulatory requirements.
• Participate in Process Hazard Analyses (PHA) including HAZOP, HAZID, and FMEA studies to identify and mitigate process hazards.
• Lead or support Management of Change (MOC) reviews for modifications to process equipment, chemicals, operating procedures, or control systems.
• Support Pre‑Startup Safety Reviews (PSSR) and Operational Readiness Reviews (ORR) for new, modified, or idled processes prior to startup.
• Maintain and update Process Safety Information (PSI) including process flow diagrams, P&IDs, and operating limits.
• Lead or participate in incident investigations and root cause analyses for process safety events, equipment failures, and near misses.
• Support regulatory inspections, internal audits, and compliance reporting related to PSM elements.

• Collaborate with operations, maintenance, and EHS teams to troubleshoot process issues and implement safe, sustainable solutions.
• Monitor and analyze process data to ensure operation within defined safe operating limits and identify opportunities for improvement.
• Develop, review, and maintain process documentation, including operating procedures, process flow diagrams, and engineering standards.
• Implement and monitor process control strategies to maintain stable and safe operating conditions.
• Provide technical support during process startups, shutdowns, and plant outages.
• Assist in training operators and technical staff on process changes, safety requirements, and updated procedures.

• Apply operational excellence and lean manufacturing principles to improve safety, productivity, and process reliability.
• Lead continuous improvement initiatives focused on yield improvement, waste reduction, energy efficiency, and process capability.
• Utilize Lean and problem‑solving tools such as root cause analysis, Kaizen, 5S, and value stream mapping to eliminate inefficiencies.
• Analyze production and process data to identify trends and implement data‑driven improvements.

• Lead or support small capital projects including scope development, design review, equipment specification, and commissioning.
• Serve as the manufacturing representative on larger capital projects, supporting design reviews, P&t, and operability assessments.
• Participate in equipment and system design reviews to ensure operability, maintainability, and safety requirements are met.
• Support commissioning and startup activities for new equipment and process improvements.

• Bachelor’s degree in chemical engineering, mechanical engineering, or related engineering discipline.
• 5+ years of experience in manufacturing, chemical processing, or industrial production environments.
• Experience working in or…