Senior Manufacturing Process Engineer

The Sr. Manufacturing/Process Engineer is responsible for designing, implementing, and optimizing manufacturing processes, equipment layouts, and production systems for a new chlorine-based web conversion, filling, and packaging facility. This role plays a critical part in establishing the facility's operational foundation, ensuring processes are safe, efficient, scalable, and compliant with applicable chemical and environmental regulations. The ideal candidate brings hands-on experience in an industrial or chemical manufacturing environment, has participated in starting up manufacturing lines, and thrives in a fast-paced, build-from-the-ground-up culture where they will wear many hats.

Essential Functions:

• Design, develop, and implement manufacturing processes and workflows from the ground up, ensuring efficiency, safety, product quality, and scalability.
• Evaluate and select equipment, tooling, and materials appropriate for chemical web conversion, filling, and packaging operations.
• Create and maintain plant layouts, process flow diagrams, SOPs, and standardized work instructions for all manufacturing machines, ensuring clarity, compliance, and operational efficiency.
• Establish chemical handling procedures for hazardous chlorine materials, including safe storage, transfer, and processing through filling and packaging equipment.
• Develop, document, and monitor critical process parameters and production data, applying statistical process control (SPC) to maintain consistent quality and drive continuous improvement.
• Conduct time studies, capacity analyses, and workflow assessments to identify and eliminate bottlenecks and waste; lead or support Lean, Six Sigma, and cost-reduction projects.
• Lead and coordinate Engineering Change Orders (ECOs) to ensure changes are properly documented, approved, and implemented in compliance with safety, quality, and regulatory standards.
• Collaborate with operations, quality, maintenance, R&D, and safety teams to ensure manufacturing processes meet product specifications and regulatory requirements and to improve production reliability.
• Provide technical oversight and troubleshooting support for production equipment and chemical handling systems; work directly with operators to resolve issues and implement corrective actions.
• Participate in review and disposition of nonconforming materials and products per product/process specifications and business requirements.
• Support facility startup activities including equipment commissioning, qualification, validation, and first production runs.
• Ensure compliance with OSHA, EPA, and applicable chemical safety regulations including PSM/RMP where required; lead hazard analyses (HAZOP, FMEA) and participate in safety audits and incident investigations.
• Develop and deliver training for operators, technicians, and junior engineers on new processes, equipment, safe chlorine handling, and safety protocols.
• Track and report key manufacturing KPIs, recommend and implement continuous improvement initiatives, and partner with leadership to build out the engineering function as the organization grows.
• Other duties as assigned.

Job Qualifications:

• Bachelor's degree in Manufacturing Engineering, Industrial Engineering, Chemical Engineering, Mechanical Engineering, or a closely related field required.
• 5-10 years of manufacturing or process engineering experience in an industrial production environment; candidates with 3-5 years and strong line startup experience considered.
• Demonstrated experience with process design, plant layout, and equipment commissioning in a new or expanding facility; line startup experience (leading or participating) required; greenfield launch experience strongly preferred.
• At least 1 year in hazardous chemical manufacturing or chlorine handling strongly preferred; web conversion, filling, or packaging experience a plus.
• Working knowledge of Lean Manufacturing, Six Sigma, SPC, or other continuous improvement methodologies; certification a plus.
• Experience conducting hazard analyses (HAZOP, FMEA) and familiarity with OSHA PSM, EPA RMP, GHS/SDS requirements, and other applicable regulatory frameworks.
• Experience developing SOPs, work instructions, technical documentation, and ECOs.
• Strong analytical and problem-solving skills with attention to detail and the ability to work independently in a dynamic environment with evolving resources.
• Highly organized and flexible; comfortable wearing many hats in a lean, startup environment, with excellent communication and…