Process Engineer, R&D

PDI - Brand; Woodcliff Lake (NJ); On-site; USD 100,000 - 150,000; Full time

Benefits offered by this job

Medical coverage

401(k) plan with match

Life insurance

FSAs

Disability benefits

Employee Assistance Program (EAP)

Vacation & holidays

Job summary

PDI is seeking a Process Engineer, R&D to lead process development, scale-up, and commercialization from bench to full-scale manufacturing. You will bridge R&D, Operations and external partners, designing bench and scale-up trials, and delivering robust process windows for launch.

With 4–8+ years in related manufacturing, you will drive PFMEA, DOE, and process capability studies, ensure on-time documentation, and support third-party manufacturers while advancing Lean/Six Sigma improvements.

Qualifications

• BS in Chemical, Mechanical, Industrial, or related Engineering field required; MS preferred.
• 4–8+ years in process development, new product introduction, scale-up, or commercialization within consumer products, medical device, pharmaceutical, or related manufacturing.
• Experience with liquid filling, nonwoven converting, or packaging operations preferred.

Responsibilities

• Translate product requirements and CTQ attributes into scalable process parameters and control plans.
• Plan and execute bench, scale-up, and line validation trials, including DOE studies.
• Lead technology transfer from R&D to Manufacturing, including SOPs, equipment setup, and operator training.
• Define and recommend the full manufacturing process and secure approvals before launch.
• Partner with multiple functions to deliver first-time-right product launches.
• Identify, evaluate, and qualify third-party manufacturers to meet quality and regulatory standards.
• Assess and qualify new equipment, tooling, and raw materials for scale-up.
• Lead PFMEA, DFM/DFR reviews, and process capability studies for first-pass yield.
• Track launch KPIs and implement corrective actions as needed.
• Drive continuous improvement using Lean/Six Sigma to reduce cost and variability.
• Maintain audit-ready technical documentation.
• Champion safe work practices and ensure EHS compliance.
• Participate in root cause investigations.

Skills

Cross-functional collaboration

Communication

DOE

SPC

PFMEA

Control plan development

Leadership of factory trials

Prioritization & accountability

Education

Bachelor's degree in Chemical Engineering

Bachelor's degree in Mechanical Engineering

Bachelor's degree in Industrial Engineering

MS preferred

Tools

DOE

SPC

PFMEA

Control plans

Job description

The Process Engineer, R&D leads process development, scale-up, and commercialization of new and redesigned products from bench through scale-up trials and into full-scale manufacturing, serving as the critical bridge between R&D, Operations, and external partners to ensure first-time-right launches. This role designs and executes bench and scale-up trials on production and partner assets, generates data to inform scale-up decisions, and establishes robust process windows for commercialization. As PDI builds internal pilot-scale capability, this role will define its requirements and lead pilot trials as a growing focus of the position. It also supports Procurement and Supply Chain in identifying, technically evaluating, and onboarding third-party manufacturers (CMOs/contract fillers/packagers), confirming they can meet PDI’s quality, regulatory, and cost standards. Through strong collaboration with internal teams and external partners, this position ensures product launches are delivered safely, compliantly, on-time, and on-cost, while driving continuous improvement in process capability and efficiency.

ESSENTIAL FUNCTIONS AND BASIC DUTIES

• Translate product requirements and critical-to-quality attributes into scalable process parameters and control plans.
• Plan and execute bench, scale-up, and line validation trials, including DOE studies, to establish robust process windows and readiness for launch.
• Lead technology transfer from R&D to Manufacturing, including SOPs, equipment set-up, and operator training.
• Define and recommend the full manufacturing process — equipment, materials, process parameters, and controls — and issue formal, data-backed recommendations to Operations Engineering so scale-up, manufacturing line/asset selection, and CMO qualification decisions are validated before launch rather than resolved on the production floor.
• Partner with Packaging, Formulation, Quality, Regulatory, Supply Chain, and Operations to deliver first-time-right product launches.
• Partner with Procurement and Supply Chain to identify, evaluate, and qualify third-party manufacturers (CMOs, contract fillers/packagers), including technical capability assessments, pilot production readiness, and alignment with PDI’s quality and regulatory standards.
• Assess, specify, and qualify new equipment, tooling, and raw materials required for scale-up and commercialization, ensuring alignment with manufacturing capability, automation opportunities, QMS, and EHS requirements.
• Lead PFMEA, DFM/DFR reviews, and process risk assessments, and own the DOE and process capability studies that drive first-pass yield, to ensure smooth commercialization and regulatory compliance.
• Track launch KPIs (e.g., yield, cycle time, scrap, OEE, COGS) and implement corrective actions as needed.
• Drive continuous improvement using Lean/Six Sigma tools to reduce cost and variability across processes.
• Maintain accurate, audit-ready technical documentation throughout the development and launch lifecycle.
• Champion safe work practices and ensure compliance with EHS requirements in laboratory and manufacturing environments, and in pilot plant environments as that capability is established.
• Participate in root cause investigations for process-related challenges.

PERFORMANCE MEASUREMENTS

• Bench-to-plant scaling accuracy within ±10% of target process parameters.
• First-pass yield ≥95% within 30 days of launch.
• Provide validated process documentation and controls to support Manufacturing in achieving minimal scrap during launch and production startup
• OEE and throughput meet or exceed business case assumptions.
• On-time, in-full delivery of process documentation, SOPs, and control plans.
• Positive cross-functional feedback on collaboration and technical leadership.

EDUCATION/CERTIFICATION:

• BS in Chemical, Mechanical, Industrial, or related Engineering field required; MS preferred.

EXPERIENCE REQUIRED:

• 4–8+ years in process development, new product introduction, scale-up, or commercialization within consumer products, medical device, pharmaceutical, or related manufacturing; experience with liquid filling, nonwoven converting, or packaging operations preferred.

SKILLS/ABILITIES:

• Strong cross-functional collaboration and communication skills.
• Hands-on experience with DOE, SPC, PFMEA, and control plan development.
• Demonstrated success in leading factory trials and product launches.
• Ability to manage multiple priorities with urgency and accountability.

WORKING CONDITIONS:

• Office, laboratory, and manufacturing floor environments; pilot plant environments as that capability is established.
• Requires occasional lifting (<25 lbs.), standing for trials, and use of PPE.
• Limited travel (<15%) to manufacturing sites, suppliers, or external partners.

Applicants must be legally authorized to work in the United States without the need for current or future employer-sponsored visa sponsorship.

SALARY RANGE

PDI is pleased to offer a comprehensive and affordable benefits program to our associates, which includes:

• Medical & prescription drug coverage
• 401(k) savings plan with company match
• Basic and supplemental life insurance
• Flexible Spending Accounts (FSAs)
• Short- and long-term disability benefits
• Health Advocacy Program / Employee Assistance Program (EAP)

Many other voluntary benefit plans and perks such as:

Legal assistance, critical illness, hospital indemnity and accident coverage, discounted home/auto/rental insurance, employee discounts and pet insurance, tuition assistance, referral bonus program, paid parental leave, a health club rebate program and more

At PDI, we are also committed to helping our associates maintain a healthy and sustainable work/life balance and are proud to provide:

Sick leave, generous vacation and holiday time, paid parental leave, summer hours, flex place/flex time options

Equal Opportunity Employer/Protected Veterans/Individuals with Disabilities
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