R&D Process Engineer: Scale-Up & Launch Expert

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

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.