Process Engineer – Pharmaceutical

Location: Whippany

A contract development and manufacturing organization that specializes in producing topical, semi-solid, and liquid pharmaceutical products for both prescription and over-the-counter markets. It supports clients through formulation, scale-up, manufacturing, and packaging, with a strong focus on quality, regulatory compliance, and speed to market. POSITION SUMMARY Process Engineer - Pharmaceutical Manufacturing (Hybrid: OSD & Sterile) The Process Engineer is responsible for driving process robustness, compliance, and performance improvement across both Oral Solid Dosage (OSD) and Sterile (vials, syringes, liquids) manufacturing operations.

This role plays a key part in investigations, process validation, continuous process verification (CPV), and equipment lifecycle management. The engineer will lead initiatives in Operational Excellence, reliability engineering, and serialization and aggregation implementation to ensure consistent product quality and manufacturing efficiency. ESSENTIAL FUNCTIONS
* Lead and execute technical investigations related to process deviations, out-of-trend (OOT) results, and equipment performance issues.
* Apply root cause analysis (RCA) and develop effective CAPAs to prevent recurrence.
* Perform process risk assessments (FMEA, HACCP) and ensure alignment with QbD and control strategy principles.
* Support data trending, process monitoring, and process improvement using statistical and analytical tools.
* Develop and maintain CPV programs for commercial products across OSD and sterile manufacturing.
* Monitor Critical Process Parameters (CPPs) and Critical Quality Attributes (CQAs) to ensure continued process capability and product quality.
* Generate annual CPV reports and present findings to cross-functional and regulatory audit teams.
* Plan, execute, and document equipment qualification (IQ, OQ, PQ) and process validation activities.
* Support introduction of new equipment, process modifications, and technology transfers.
* Collaborate with Engineering, Maintenance, and QA to ensure all equipment and systems remain in a qualified state throughout their lifecycle.
* Lead and support Operational Excellence initiatives utilizing Lean, Six Sigma, and Kaizen methodologies.
* Implement reliability engineering principles (RCM, Weibull analysis, FMEA) to enhance equipment uptime and process stability.
* Identify and execute cost-reduction and yield-improvement projects while maintaining compliance and product quality.
* Manage process and equipment lifecycle activities from design through decommissioning.
* Evaluate process capability and equipment performance to recommend improvements or upgrades.
* Collaborate with global engineering and manufacturing teams on lifecycle and asset management strategies.
* Provide technical expertise for serialization and aggregation processes within OSD packaging operations.
* Ensure proper integration and qualification of serialization systems (hardware/software) with production and ERP systems.
* Support regulatory compliance for traceability and product integrity requirements. REQUIRED QUALIFICATIONS

* Education:

Bachelor"s or master"s degree in Chemical Engineering, Mechanical Engineering, Pharmaceutical Engineering, or related field.

* Experience:

o 5-10 years" experience in pharmaceutical manufacturing, covering both OSD and sterile operations. o Proven track record in process validation, CPV, and equipment qualification. o Experience in root cause investigation, CAPA management, and regulatory audits (FDA, EMA, MHRA). o Exposure to serialization and aggregation systems and related compliance standards. o Working knowledge of reliability engineering and Operational Excellence tools. Key Skills &

Competencies:

* Strong analytical and problem-solving capabilities with proficiency in tools such as Minitab, MS Project, MS Tools, etc.
* Solid understanding of cGMP, ICH Q8-Q10, Annex1, 21

CFR 210/211/820, ISO 13485 and data integrity principles.
* Excellent communication, presentation, and technical writing skills.
* Ability to work cross-functionally and manage multiple projects simultaneously.
* Self-motivated, detail-oriented, and committed to continuous improvement. Preferred

Certifications:

* Lean Six Sigma Green Belt / Black Belt
* Certified Reliability Engineer (CRE)
* PMP (Project Management Professional) - desirable By applying for this job, you agree to receive calls, Al-generated calls, text messages, or emails from Synerfac Technical Staffing and our contracted partners. Frequency varies for text messages. Message and data rates may apply. Carriers are not liable for delayed or undeliverable messages. You can reply STOP to cancel and HELP for help.

You can access our privacy policy at