Senior Process Engineer

The Senior Process Engineer will be located onsite in Pueblo, CO and reports to the Manufacturing Engineering Manager. This role is responsible for owning the end‑to‑end process lifecycle — spanning early development and feasibility through scale‑up, process qualification, and production readiness — in close collaboration with cross‑functional teams across Engineering, Manufacturing, Quality, Safety, and Compliance.

• Own the end‑to‑end process lifecycle — spanning early development and feasibility through scale‑up, process qualification, and production readiness — in close collaboration with cross‑functional teams across Engineering, Manufacturing, Quality, Safety, and Compliance.
• Design, develop, and implement manufacturing processes, procedures, tooling, and systems for solid rocket motors and energetic materials, ensuring adherence to safety, quality, performance, and reliability standards throughout the product lifecycle.
• Lead the transition of energetic manufacturing processes from development and pilot scale to full production standing, defining process controls, qualification criteria, and production readiness gates.
• Implement Lean Manufacturing and Six Sigma methodologies to deliver measurable improvements in safety, quality, reliability, cost, and throughput; develop and report on key process performance metrics such as yield, defect rates, and cycle time.
• Create, review, and maintain Standard Operating Procedures (SOPs), work instructions, process specifications, and technical documentation to production standards.
• Prepare technical reports and presentations for internal and external stakeholders to support planning, budgeting, process reviews, and program milestones; stay current with energetics processing and manufacturing industry trends.
• Mentor and guide junior engineers and technicians in process engineering fundamentals, safe handling of energetic materials, and manufacturing best practices.

• Bachelor’s degree in Mechanical, Aerospace, Chemical, Materials Science, or other relevant engineering discipline with 7 years of experience in process engineering, manufacturing engineering, or a related field OR Master’s degree in a relevant field with 5 years of experience OR 11 years of hands‑on process and manufacturing engineering experience in lieu of a degree.
• Demonstrated experience leading process development and scale‑up from early‑stage feasibility through production qualification in a manufacturing environment.
• Excellent verbal and written communication skills, with the ability to clearly convey technical concepts through the development and maintenance of SOPs, work instructions, process specifications, and technical documentation aligned with production standards.
• Proven ability to implement Lean Manufacturing and Six Sigma methodologies with measurable results in process improvement, yield, or throughput.
• Experience applying structured root cause analysis and corrective action methodologies (e.g., 8D, fishbone, 5‑Why) to manufacturing nonconformances and process deviations.
• Ability to collect, analyze, and interpret process data to drive engineering decisions and support continuous improvement, even in low‑volume or novel manufacturing environments.
• Strong self‑starter with the ability to solve complex problems from first principles with minimal supervision, both independently and as a contributing team member in a fast‑paced startup environment.
• Demonstrated commitment to safety culture and ability to operate within rigorous regulatory environments including OSHA, ITAR, and hazardous/energetic materials standards.

• Experience with energetic materials, solid rocket motor propellant chemistry, or other hazardous manufacturing environments.
• Lean Manufacturing or Six Sigma certification (Green or Black Belt) with demonstrated application in automated production environments.

• Travel up to 15%, including the possibility of overnights within the continental United States.
• Ability to lift, move, or carry items or equipment up to 50 pounds. Comfortable standing, walking, climbing,…