Senior Operations Engineer - Spray Drying
Merck
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Job summary
Merck in Elkton, VA is seeking a Senior Operations Engineer - Spray Drying to support commissioning, qualification, start-up, and readiness of a new Small Molecule facility. You will partner with Operations, Engineering, Quality, and other teams to ensure safe, compliant plant start-up and continuous improvement.
The role requires a Bachelor's in a technical field and at least 5 years in Drug Product/SDI manufacturing, with strong GMP knowledge.
Qualifications
- Bachelor's degree required in a technical discipline; Chemical/Pharmaceutical/Biochemical preferred.
- Minimum 5 years of experience in Drug Product/SDI manufacturing or related spray drying operations.
- Experience working in cross-functional manufacturing, technical, or operational settings.
- Experience with GMP, quality, and compliance in pharma manufacturing.
Responsibilities
- Support commissioning, qualification, start-up, and operational readiness for the new SDI Small Molecule facility in Elkton, VA.
- Collaborate with Operations, Engineering, Quality, Technical Operations, and Supply Chain to ensure safe, compliant start-up.
- Provide technical and operational support during equipment and process start-up, troubleshooting, and optimization.
- Support technology transfer and implementation of commercial processes into the new facility.
- Help define and improve operating practices, standard work, and procedures for reliable operations.
- Coordinate improvement activities and focus areas within the IPT aligned with business goals.
- Apply lean principles (Kaizen, 5S, visual management, Standard Work) to identify improvements.
- Embed best practices across shifts and functions to promote consistency and execution.
- Foster a culture of safety, quality, compliance, and continuous improvement.
Skills
Education
Tools
Job description
At our company, we aspire to be the premier research-intensive biopharmaceutical company, using the power of leading-edge science to save and improve lives around the world. We are at the forefront of research to deliver innovative health solutions that advance the prevention and treatment of diseases in people and animals.
Production Lead, DP&SDI
The Senior Operations Engineer - Spray Drying supports the DP and SDI Integrated Product Team (IPT) in the commissioning, qualification, start-up, and operational readiness of the new Small Molecule manufacturing facility in Elkton, Virginia. This role partners with cross-functional teams to help ensure safe, compliant, and efficient operations during project execution and through ongoing manufacturing. In addition, the SDI Operations Engineer helps coordinate and prioritize improvement activities and areas of focus across the IPT, supporting continuous improvement and operational excellence as the facility transitions into routine operations.
- Support commissioning, qualification, start-up, and operational readiness activities for the new SDI Small Molecule facility in Elkton, VA.
- Partner with Operations, Engineering, Quality, Technical Operations, Supply Chain, and other stakeholders to support safe, compliant, and effective plant start-up.
- Provide technical and operational support during equipment and process start-up, troubleshooting, and optimization activities.
- Support technology transfer and implementation of commercial manufacturing processes into the new facility.
- Help define, implement, and improve operating practices, standard work, procedures, and routines that support reliable and compliant operations.
- Coordinate and prioritize improvement activities and key areas of focus within the IPT in alignment with business objectives and operational performance goals.
- Use our company Production System (MPS) tools and lean principles, including Kaizen, 5S, visual management, and Standard Work, to identify and support improvement opportunities.
- Help embed best practices across shifts, functions, and workstreams to promote consistency, efficiency, and strong operational execution.
- Support a culture of safety, quality, compliance, accountability, and continuous improvement.
- Act as a delegate for the Production Lead when needed, supporting continuity of leadership and cross-functional coordination.
- Contribute to an inclusive, collaborative, and performance-driven work environment.
- Bachelor’s degree required. Chemical Engineering, Pharmaceutical Engineering, Biochemical Engineering, Chemistry, or a related technical discipline preferred.
- Minimum 5 years of experience in Drug Product/SDI manufacturing, operations, technical operations, or a related manufacturing experience in Spray Drying.
- Experience working in a cross-functional manufacturing, technical, or operational setting.
- Experience contributing to operational improvement, troubleshooting, process support, or start-up-related activities.
- Working knowledge of GMP, quality, and compliance expectations in pharmaceutical manufacturing.
- Strong problem-solving, communication, collaboration, and organizational skills.
- Ability to work effectively across Operations, Engineering, Quality, and Technical teams.
- Ability to prioritize work in a dynamic, fast-paced environment.
- Demonstrated commitment to safety, operational excellence, and continuous improvement.
- Experience supporting commissioning, qualification, start-up, or validation activities.
- Experience in a greenfield or new facility start-up environment.
- Experience with technology transfer and implementation of commercial manufacturing processes.
- Experience applying lean tools and methodologies, including Kaizen, 5S, and Standard Work.
- Experience coordinating activities across shifts, teams, or functions.
- Experience serving in a lead, coordinator, or delegate role supporting leadership continuity.
- Experience identifying improvement opportunities and helping implement practical solutions in a manufacturing environment.
This is a unique opportunity to help shape the future of a growing Small Molecule site as it is established from the ground up. In this role, you will support the startup and operational readiness of the new facility, help establish effective ways of working, and contribute to continuous improvement efforts that enable safe, reliable, and high-quality medicine production for patients around the world. If you are a collaborative operations professional with strong technical acumen, a commitment to quality, and a passion for operational excellence, we encourage you to apply.
#ELKVACOE
Adaptability, Adaptability, Analytical Problem Solving, Business Process Improvements, cGMP Compliance, Chemical Engineering, Cross-Functional Project Management, Data Analysis, Decision Making, Engineering Support, Focused Improvement, Inventory Management, Leadership Theories, Lean Six Sigma Continuous Improvement, Manufacturing, Manufacturing Processes, Manufacturing Strategies, Manufacturing Systems, Manufacturing Technologies, Operational Quality, Operations Engineering, Personal Initiative, Pharmaceutical Process Engineering, Process Improvements, Process Optimization {+ 8 more}
Business Acumen, Change Management, Communication, Conflict Management, Continuous Improvement, Cost Reduction, Decision Making, Design, Leadership, Leadership Development, Leadership Style, Medical, Multi‑Tasking, Operational, Process Improvement, Problem Solving, Problem Solving, Project Management, Quality, Remote Work, Safety, Team Building, Teamwork, Technical Support, Technical Writing, Time Management, Working with Complex Machinery & Devices, Working With Documentation, Working with Lean & Six Sigma, Working with Measurements, Working with Monitoring Systems, Working with SAP, Working with Standards, Working with Technical Assistance, Working with Technical Assistance, Working with Technical Support, Working with Technical Writing, Working With 6σ, Working with 6σ, Working with Multiple Systems, Working with Project Management, Working with Safety, Working with Safety, Working with Safety Systems, Working with Systems, Working with Tools, Working with Technology, Working with Varied People, Working with Varying Work Hours, Working with Variables, Working Without Guidelines, Working Without Instructions, Working Without Information, Working with Continuous Improvement, Working with Lean, Working with SAP, Working with Standards, Working with Medical Devices, Working With Regulations, Working With Standards, Working With Standards, Working With Stability, Working with Six Sigma, Working With Systems, Working With Safety, Working With Value Stream, Working With Agile, Working With Business, Working With Departments, Working With Document Control, Working With Industry Standards, Working With IT, Working With Mac, Working With Minimum Standards, Working With Mx, Working With NPI, Working With Numbers, Working With Processes, Working With Reporting, Working With Safety & Ethics, Working With Six Sigma, Working With Standards, Working With Standards, Working With Systems, Working With Technical Issues, Working With Thermodynamics, Working With Tools, Working With TPM software, Working With Vehicles, Working With Vine, Working With Woven, Working With Workers, Working With Workflows, Working With Writing, Working With Zoë, Working with Zorro, Working with Intervention, Working With Non‑Prod Systems, Working With Non‑Production Systems, Working with Non‑Production Systems
Our company is committed to inclusion, ensuring that candidates can engage in a hiring process that exhibits their true capabilities.
As an Equal Employment Opportunity Employer, we provide equal opportunities to all employees and applicants for employment and prohibit discrimination on the basis of race, color, age, religion, sex, sexual orientation, gender identity, national origin, protected veteran status, disability status, or other applicable legally protected characteristics. As a federal contractor, we comply with all affirmative action requirements for protected veterans and individuals with disabilities. For more information about personal rights under the U.S. Equal Opportunity Employment laws, visit: EEOC Know Your Rights EEOC GINA Supplement We are proud to be a company that embraces the value of bringing together, talented, and committed people with diverse experiences, perspectives, skills and backgrounds. The fastest way to breakthrough innovation is when people with diverse ideas, broad experiences, backgrounds, and skills come together in an inclusive environment. We encourage our colleagues to respectfully challenge one another’s thinking and approach problems collectively.
Learn more about your rights, including under California, Colorado and other US State Acts
USA - Virginia - Elkton
Where required by law, the compensation range for this role is provided below. The salary range for the primary location of this role is: $96,200.00 - $151,400.00 This range reflects the Company‘s reasonable expectation of the base salary applicable to this role at the time of posting. An employee’s position within the salary range will be based on several factors including, but not limited to relevant education, qualifications, certifications, experience, skills, geographic location, government requirements, and business or organizational needs. The successful candidate will be eligible for annual bonus and long-term incentive, if applicable.
We offer a comprehensive package of benefits. Available benefits include medical, dental, vision healthcare and other insurance benefits (for employee and family), retirement benefits, including 401(k), paid holidays, vacation, and compassionate and sick days. More information about benefits is available at https://jobs.merck.com/us/en/compensation-and-benefits.
Please note the salary range above applies to the Primary Location of the position. Where a role has other listed locations, different compensation guidelines may apply. You may find the salary ranges for additional locations below. If the salary range is not listed for the location you are applying to, our Talent Acquisition team will provide further information to you relevant to your location.
San Francisco Residents Only: We will consider qualified applicants with arrest and conviction records for employment in compliance with the San Francisco Fair Chance Ordinance
Los Angeles Residents Only: We will consider for employment all qualified applicants, including those with criminal histories, in a manner consistent with the requirements of applicable state and local laws, including the City of Los Angeles’ Fair Chance Initiative for Hiring Ordinance
Regular
Domestic
No
10%
Not Applicable
1st - Day
No
NA
10/26/2026
A job posting is effective until 11:59:59PM on the day BEFORE the listed job posting end date. Please ensure you apply to a job posting no later than the day BEFORE the job posting end date.
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