Process Safety Engineer

Sterling Pharma Solutions; Town of Germantown (WI); On-site; USD 85,000 - 120,000; Full time

Job summary

Sterling Pharma Solutions in Wisconsin is seeking a Process Safety Engineer to help ensure our chemical manufacturing processes are safe, compliant, and efficient. You will work with engineering, operations, maintenance, and EHS teams to evaluate hazards and implement improvements.

This role is ideal for someone early in their engineering or safety career eager to gain hands-on experience in risk assessment, regulatory compliance, and continuous improvement within a pharmaceutical manufacturing

Qualifications

• Bachelor’s degree in engineering, chemistry, occupational safety or related field.
• 3 years of experience in a PSM-covered facility.
• Willingness to travel up to 10%.

Responsibilities

• Assist with OSHA PSM program implementation and maintenance.
• Prepare written documentation, reports, and presentations related to process safety.
• Support PHAs, RCAs, and incident investigations.
• Assist in MOC documentation and process safety audits.

Skills

Process safety

Hazard analysis

Regulatory compliance

Risk assessment

Communication

Safety culture

Education

Bachelor’s degree in engineering, chemistry, occupational safety or related discipline

Tools

Microsoft Office

Job description

Process Safety Engineer

Summary of Role

As a Process Safety Engineer, you'll help ensure our chemical manufacturing processes are safe, compliant, and operating efficiently. Working alongside engineering, operations, maintenance, and EHS teams, you'll evaluate process risks, participate in hazard reviews and incident investigations, support equipment and process changes, and help implement improvements that protect employees, the environment, and our facility.

This role is ideal for someone early in their engineering or safety career who wants hands‑on experience in process safety while developing expertise in risk assessment, regulatory compliance, and continuous improvement within a pharmaceutical manufacturing environment. The position requires execution of the Sterling Values and non‑negotiables, as well as expertise in functional competencies included in this position profile.

Essential Functions

• Assist with the implementation and maintenance of the sites OSHA Process Safety Management (PSM) program.
• Supports and completes preparation of written documentation, reports, and presentations related to process safety activities.
• Help identify process safety improvement opportunities through collaboration with team members and stakeholders.
• Assist in updating process safety–related Standard Operating Procedures (SOPs), engineering standards, and guidelines.
• Participate in Process Hazard Analyses (PHAs) as a team member and work toward facilitator qualification.
• Help track PHA recommendations and verify follow ‑ up actions.
• Participate in incident investigations and learn root cause analysis (RCA) methods.
• Support Pre ‑ Startup Safety Reviews (PSSR) and process safety audits.
• Assist in developing and delivering basic process safety training materials.
• Support the Management of Change (MOC) process by helping maintain documentation and workflow accuracy.
• Collaborate with project managers on capital and operational projects to ensure safety considerations are addressed.
• Assist with preparing regulatory reports and documentation for submission.
• Participate in customer or regulatory audits as needed.
• Complete all required cGMP and company training in a timely manner.
• An individual in this position must be able to successfully perform the essential duties and responsibilities listed above. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions of this position.

Key Competencies

• Foundational understanding of process safety, chemical engineering principles, or EHS concepts (coursework or internship experience acceptable).
• Strong communication skills and ability to prepare clear documentation.
• Willingness to learn PHA, RCA, and other process safety methodologies.
• Ability to support audits, inspections, and risk assessments under guidance.
• Interest in fostering a strong safety culture and engaging with employees at all levels.
• Proficiency with Microsoft Office (Outlook, Word, Excel).

Education and Experience

• Bachelor’s degree in engineering, chemistry, occupational safety or related discipline.
• Or 3 years applicable work experience in a PSM covered facility.

Travel Requirement

• Up to 10% travel may be required.

Other Qualifications, Skills and Abilities

• This position is eligible for a flexible schedule.
• This position is not eligible for remote / hybrid work location.

Diversity and Inclusion

Sterling values diversity and we are committed to creating an inclusive environment for all employees. All employment decisions are based on business needs, job requirements and individual qualifications, without regard to race, color, religion, sex, pregnancy, age, national origin, physical or mental disability, past or present military service, marital status, gender identification or expression, medical condition (including genetic characteristics) or any other protected characteristic as established by law.

Why Consider Sterling?

Sterling Pharma Solutions is a global contract development and manufacturing organisation (CDMO) with more than 50 years’ experience in developing and manufacturing Active Pharmaceutical Ingredients (APIs). This is complimented by Antibody Drug Conjugate (ADC) research and development bioconjugation services.

We are a fast growing, dynamic business with facilities in the UK and the US, where we employ more than 800 talented and passionate people who support our customers in bringing new medicines to market, improving and saving the lives of patients.

Our culture and our way of working is what really sets us apart as a business; we aim to deliver an exceptional experience to our customers and our employees. You can expect to be part of a supportive team, all working towards a shared goal: to deliver first-class science and service to our customers every day.