Process Safety Manager

Insight Global; Austin (TX); On-site; USD 120,000 - 150,000; Full time

Job summary

Insight Global, on behalf of our client, is seeking a Process Safety Engineer to lead and enhance process safety programs across advanced semiconductor manufacturing operations. The role focuses on identifying, assessing, and mitigating process safety risks while supporting regulatory compliance and operational excellence.

The ideal candidate will bring experience from semiconductor manufacturing or similar regulated chemical environments, collaborating cross-functionally with process,

Qualifications

• Bachelor’s degree in Chemical Engineering, Process Safety, or related field.
• 5+ years of process safety experience in semiconductor manufacturing or similar complex chemical environments.
• Experience leading PHAs, HAZOPs, DHAs, LOPAs.
• Knowledge of OSHA PSM and EPA RMP regulations.
• Ability to read P&IDs, PFDs, CAD drawings, and construction documents.
• Strong project management and stakeholder communication.

Responsibilities

• Lead risk assessments including HAZID, HAZOP, LOPA, FMEA, DHA, and Offsite Consequence Analysis (OCA) for hazardous materials and manufacturing processes.
• Develop and implement risk mitigation strategies for pyrophoric, toxic, corrosive, and reactive chemicals used in semiconductor manufacturing.
• Ensure compliance with OSHA PSM, EPA RMP, SEMI standards, and other applicable safety regulations.
• Conduct safety-focused design reviews for manufacturing equipment, utility systems, and chemical distribution processes.
• Perform process safety analyses related to emergency relief systems, toxic gas dispersion, flammability hazards, EAC, and vent abatement systems.
• Partner with engineering, facilities, and operations teams to implement engineering controls and safe work practices.
• Support facility startup activities, PSSR, equipment commissioning, and qualification efforts.
• Lead incident investigations, MOC processes, and EHS audits to drive continuous improvement.
• Promote a proactive safety culture throughout manufacturing operations.

Skills

PHAs & HAZOPs

PSM & RMP knowledge

Cross-functional collaboration

Regulatory interpretation

Project management

Communication skills

Education

Bachelor's in Chemical Engineering or Process Safety

Job description

Our client is building a state-of-the-art semiconductor manufacturing facility and is seeking a Process Safety Engineer to lead and enhance process safety programs across advanced manufacturing operations. This role focuses on identifying, assessing, and mitigating process safety risks associated with semiconductor fabrication processes while supporting operational excellence, production goals, and regulatory compliance.

The ideal candidate will have experience working in semiconductor manufacturing or another highly regulated chemical/process manufacturing environment and will be comfortable partnering cross-functionally with process, equipment, facilities, and operations teams.

Key Responsibilities

• Lead and facilitate risk assessments including HAZID, HAZOP, LOPA, FMEA, DHA, and Offsite Consequence Analysis (OCA) for hazardous materials and manufacturing processes.
• Develop and implement risk mitigation strategies for pyrophoric, toxic, corrosive, and reactive chemicals commonly used in semiconductor manufacturing.
• Ensure compliance with OSHA Process Safety Management (PSM), EPA Risk Management Program (RMP), SEMI standards, and other applicable safety regulations.
• Conduct safety-focused design reviews for manufacturing equipment, utility systems, and chemical distribution processes.
• Perform process safety analyses related to emergency relief systems, toxic gas dispersion, flammability hazards, Electrical Area Classification (EAC), and vent abatement systems.
• Partner with engineering, facilities, and operations teams to implement engineering controls and safe work practices.
• Support facility startup activities, Pre-Startup Safety Reviews (PSSR), equipment commissioning, and qualification efforts.
• Lead incident investigations, Management of Change (MOC) processes, and EHS audits to drive continuous improvement and operational excellence.
• Promote a proactive safety culture throughout manufacturing operations.

Required Qualifications

• Bachelor’s degree in Chemical Engineering, Process Safety, or a related engineering discipline, or equivalent industry experience.
• 5+ years of process safety experience in semiconductor manufacturing or a similarly complex chemical/process manufacturing environment.
• Hands-on experience leading and facilitating PHAs, HAZOPs, DHAs, LOPAs, or related risk assessments.
• Strong knowledge of OSHA PSM, EPA RMP, and applicable state and federal safety regulations.
• Ability to read and interpret P&IDs, PFDs, CAD drawings, and construction/design documents.
• Experience translating regulatory requirements into practical operational and engineering solutions.
• Strong project management skills with the ability to manage multiple priorities in a fast-paced environment.
• Excellent communication and stakeholder management skills.

Preferred Qualifications

• Direct experience supporting semiconductor fabrication facilities.
• Familiarity with deposition, etch, lithography, CMP, diffusion, clean, thermal processing, or related semiconductor manufacturing processes.
• Experience supporting facility startups, tool commissioning, and high-volume manufacturing environments.
• Knowledge of hazardous gas systems, chemical distribution systems, and cleanroom operations.