Senior Process Engineer – Manufacturing Operations

CompoSecure • Somerset, NJ

11h • Onsite

About The Position

The Senior Process Engineer – Manufacturing Operations will work five days a week on-site in Somerset, NJ. We are seeking an experienced and technically accomplished Senior Process Engineer to play a critical leadership role within our high volume, 24/7 manufacturing operations. This position is responsible for owning process performance, driving yield and efficiency improvements, and leading technical execution for new product introductions (NPI) in a fast-paced production environment. As a senior individual contributor, this role serves as a technical authority and mentor, partnering closely with Operations, Quality, Maintenance, Supply Chain and Engineering teams to ensure robust, scalable, and compliant manufacturing processes. The Senior Process Engineer is expected to apply deep engineering expertise, structured problem-solving methodologies, and data driven decision making to deliver measurable improvements in yield, quality, cost, and delivery.

Requirements

• Bachelor's degree in Manufacturing, Mechanical, Industrial, Chemical Engineering, or a related engineering discipline.
• 5+ years of progressive experience in a high volume manufacturing environment, preferably supporting 24/7 operations.
• Demonstrated expertise in process optimization, yield improvement, and advanced troubleshooting.
• Proven experience leading or owning NPI process development and production readiness activities.
• Strong working knowledge of Lean Manufacturing, Six Sigma, SPC, and statistical analysis techniques.
• Proficiency with data analysis and manufacturing systems (Excel, Minitab, ERP).
• Excellent communication and collaboration skills, with the ability to influence across shifts and functions.

Nice To Haves

• Experience in regulated manufacturing environments (e.g., medical device, electronics, automotive, aerospace) preferred.
• Lean or Six Sigma certification (Green Belt or higher) strongly preferred.
• Hands on experience with automation, sensors, or high throughput manufacturing equipment.

Responsibilities

• Provide advanced, real time process engineering support to production teams during the shift, ensuring rapid issue resolution and sustained equipment and process performance.
• Serve as the technical owner for assigned process areas, leading root cause investigations related to yield loss, scrap, rework, downtime, and quality escapes using structured methodologies (SPC, FMEA, DMAIC, 5 Whys, Fishbone).
• Lead and execute yield improvement and continuous improvement initiatives, translating data insights into sustainable corrective and preventive actions that improve throughput, cost, and process capability.
• Provide senior level engineering leadership for New Product Introduction (NPI) activities, including operator friendly process development, validation, work instruction authoring (SOP), training on SOP, and production ramp up readiness.
• Collaborate cross functionally with Quality, Operations, Maintenance, Supply Chain, and Engineering to align process capability with business, customer, and regulatory requirements.
• Develop, review, and maintain standard operating procedures (SOPs) and training materials, ensuring clarity, accuracy, and audit readiness.
• Monitor, analyze, and report key performance indicators (KPIs) related to yield, cycle time, downtime, and quality; proactively drive action plans based on trends and risk.
• Act as a technical mentor and coach to junior engineers, technicians, and manufacturing personnel, fostering a culture of continuous improvement and technical excellence.
• Support customer visits, audits, and internal reviews as a process subject matter expert, representing manufacturing capabilities with professionalism and technical credibility.
• Ensure ongoing compliance with safety, quality, and regulatory standards applicable to manufacturing operations, proactively identifying and mitigating process risk.
• Lead new material/vendor qualification projects collaboration with Supply Chain, Engineering, Production, Quality team with project documentation including risk assessment, timelines and technical report.
• Demonstrate strong prioritization skills to ensure engineering effort is focused on the processes and issues with the highest business impact.
• Maintain thorough documentation of existing and new processes, including equipment parameters, validation results, and continuous improvement outcomes.
• Support special projects and other duties as required by the business.

Benefits

• We offer a comprehensive benefits package designed to support your health, financial well-being, and work-life balance, including medical, prescription, dental, and vision coverage; FSA/HSA options; company-paid life and disability insurance; 401(k) with company match; paid time off (PTO) and holidays; annual bonus opportunities; an employee assistance program (EAP); and opportunities for career growth and advancement.
• Additional details will be provided during the hiring process.

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level
• Number of Employees: 501-1,000 employees