Process Systems Engineer

Empirical Consulting Solutions, LLC; Warminster Township (Bucks County); On-site; USD 80,000 - 110,000; Full time

Job summary

Empirical Consulting Solutions, LLC seeks a Process & Systems Engineer to design, develop, and maintain systems supporting production, operations, and quality. You will bridge shop floor and engineering offices with hands-on process engineering and data systems development, including LabVIEW integration, SQL databases, and Excel reporting tools.

The role emphasizes equipment reliability, continuous improvement, and data-driven decision making, with responsibilities across PLC programming, data

Qualifications

• Bachelor’s degree in Mechanical, Electrical, or Industrial Engineering, Computer Science, or related field; or equivalent combo of education and experience.
• 3 years of hands-on experience in a manufacturing or industrial engineering environment.
• Proficiency in SQL with experience writing queries and managing databases.
• Demonstrated ability to develop Excel tools including VBA, complex formulas, and pivot tables.

Responsibilities

• Diagnose systems problems, replace/repair parts, and test adjustments.
• Monitor equipment performance; analyze failures and develop corrective actions.
• Perform root cause analysis and implement corrective/preventive actions.
• Design and develop new control system installations with Engineering/Maintenance.
• Validate improvements and hand off to production.
• Apply lean manufacturing and Kaizen/5S to improve OEE.
• Develop and maintain SOPs, work instructions, and process flow diagrams.
• Support capital project planning with equipment specs and ROI analyses.
• Program, troubleshoot, and maintain PLC control systems.
• Develop automated workflows linking data acquisition, control systems, and reporting tools.
• Develop LabVIEW VIs for monitoring and data acquisition.
• Configure NI hardware and integrate LabVIEW with SQL/Excel reporting.

Skills

LabVIEW

SQL

Excel (VBA)

Power BI

Python scripting

Education

Bachelor’s degree in Mechanical, Electrical, Industrial Engineering, or related field

Tools

LabVIEW

SQL Server

Excel

Power BI

SCADA

Job description

Job Title:Process & Systems Engineer

Reports To:Engineering Manager

FLSA Status:Exempt, Full-Time

Summary:The Process & Systems Engineer designs, develops, and maintains systems that support production, operations, and quality functions at Pressure Technology. This role combines hands‑on process engineering with data systems development — encompassing LabVIEW integration, SQL databases, Excel‑based tools, PLC programming, and industrial process monitoring. The position bridges the shop floor and engineering office, driving equipment reliability, process improvement, and data‑driven decision making.

Essential Duties and Responsibilities

include the following:

Equipment & Process Engineering

• Diagnose systems related problems, replace or repair parts, and test adjustments.
• Monitor HIP and other production equipment performance; analyze repetitive failures and develop corrective actions.
• Conduct root cause analysis and implement corrective/preventive actions to reduce downtime and improve reliability.
• Design and develop new control system installations in collaboration with the Engineering and Maintenance Managers.
• Validate systems improvements; test and approve before handoff to production.
• Apply lean manufacturing and continuous improvement methodologies (Kaizen, 5S) to optimize overall equipment effectiveness (OEE).
• Develop and maintain SOPs, work instructions, and process flow diagrams.
• Support capital project planning with equipment specifications, cost‑benefit analyses, and ROI justifications.

PLC & Automation

• Program, troubleshoot, and maintain Programmable Logic Controllers (PLCs) control systems.
• Identify and implement automation opportunities to reduce manual processes and improve workflow efficiency.
• Develop automated workflows linking data acquisition, control systems, and reporting tools.

LabVIEW & Data Acquisition

• Develop and maintain LabVIEW virtual instruments (VIs) for equipment monitoring, data acquisition, and process control.
• Configure and troubleshoot NI hardware including DAQ cards, cDAQ/cRIO chassis, and signal conditioning equipment.
• Integrate LabVIEW data streams with SQL databases and Excel reporting tools for real‑time and historical analysis.
• Maintain LabVIEW codebases, version control, and documentation per engineering standards.

SQL, Data Management & Reporting

• Write, test, and optimize SQL queries, stored procedures, and views for reporting and data retrieval.
• Utilize CMMS database to generate reports for maintenance and equipment. Develop and maintain KPI dashboards and process performance reports for engineering and operations teams.
• Validate data accuracy and investigate discrepancies or anomalies; support root cause analysis with historical trend data.

Excel Application Development

• Design and build Excel workbooks with VBA macros, advanced formulas, pivot tables, and dynamic dashboards.
• Develop calculation tools, data entry forms, and automated reporting templates.
• Optimize existing spreadsheets for performance, accuracy, and usability.

Cross‑Functional Collaboration

• Collaborate with production, quality, and engineering teams to evaluate process capability and drive corrective actions.
• Provide technical support and training to end users on developed tools and systems.
• Assist or fill in for the Maintenance Manager in his absence.
• Perform all other duties as assigned.
• Analyze and improve shop floor material flow, workstation layouts, and production sequencing to reduce waste and improve throughput.

Qualifications:

To perform this job successfully an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or ability required. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions, however, due to the design and nature of the equipment, type and size of customer parts, some accommodations may not be possible.

Required:

Bachelor’s degree in Mechanical, Electrical, or Industrial Engineering, Computer Science, or related field; or equivalent combination of education and experience. 3 years of hands‑on experience in a manufacturing or industrial engineering environment. Proficiency in SQL (SQL Server or similar) with experience writing queries and managing databases. Demonstrated ability to develop Excel tools including VBA, complex formulas, and pivot tables. Strong analytical and problem‑solving skills with attention to detail. Effective written and verbal communication skills; ability to translate technical concepts for non‑technical audiences.

Preferred:

Experience with HIP equipment or pressure vessel / ASME‑regulated environments. NI LabVIEW Certified Developer (CLD) or higher. Familiarity with SCADA, historian software, or other industrial data platforms. Experience with Power BI, Power Query, or similar business intelligence tools. Knowledge of Python or other scripting languages. Lean / Six Sigma certification or equivalent continuous improvement training. Experience with PLC programming control systems.

Key Competencies:

Technical depth across process engineering, controls, and data systems. Analytical thinking and data‑driven decision making. Continuous improvement and process‑oriented mindset. Ability to manage multiple priorities and meet deadlines. Collaborative, team‑oriented approach with strong cross‑functional communication. Commitment to safety, quality, and operational excellence.

Certificates, Licenses, Registrations:

Mandatory: Must be able meet regulatory work status requirements: I-9, US Export Control/ ITAR. Must have a valid driver’s license in good standing. Forklift certification will be provided.

Physical Demands:

While performing the duties of this job the employee is regularly required to stand for extended periods, lift objects up to 50 lbs., and occasionally climb ladders, stoop, kneel, or work in confined spaces. This is a safety‑sensitive position; mandatory overtime may be required.

Work Environment:

While performing the duties of this job the employee is exposed to both office and production floor environments, with varying temperature and noise levels. The noise level in the production area falls within acceptable limits of OSHA guidelines.