Senior Process & CI Engineer - Lean Six Sigma Leader

ADP, Inc.; Broadview (IL); On-site; USD 98,000 - 120,000; Full time

Job summary

ADP, Inc. in Broadview, IL seeks a Process/Continuous Improvement Engineer to drive design, implementation and optimization of production processes across Broadview and Blue Island, supporting liquid, hot pour, and aerosol lines.

This hands-on role requires Lean and Six Sigma leadership, cross-functional collaboration, and a strong background in chemical or mechanical engineering with 3–5 years in regulated manufacturing.

Willingness to travel between IL sites is expected.

Qualifications

• Bachelor’s degree in chemical engineering, mechanical engineering, or a related discipline.
• 3-5 years of experience in process design and engineering within a regulated manufacturing environment.
• Proven experience across the full lifecycle of process design and continuous improvement projects (design, trials, commissioning, startup).
• Strong background in chemical processes and formulation technologies (e.g., soap base-like materials).
• Hands-on experience with process technologies such as compounding, mixing, extrusion, milling, hot pour, liquid filling, aerosol filling, and pressing.
• Working knowledge of engineering design software.
• Familiarity with process-related standards, safety requirements, and regulatory guidelines.
• Strong technical, analytical, and problem-solving skills.
• Excellent verbal and written communication skills.
• Ability to manage multiple projects, prioritize tasks, and meet deadlines.
• Demonstrated leadership in cross-functional environments.
• Demonstrated experience leading Lean and/or Six Sigma continuous improvement projects with measurable results (e.g., cost savings, cycle time reduction, yield improvement).
• Ability to develop, track, and report process- and CI-related KPIs to plant and executive leadership.
• Willingness and ability to travel regularly between the Blue Island, IL and Broadview, IL facilities.

Responsibilities

• Manage full lifecycle of process design and continuous improvement projects—from concept through to commissioning and startup.
• Design, implement, and optimize new production processes with a focus on efficiency, safety, and quality.
• Conduct process development, trials, validations, and optimizations to establish robust process parameters.
• Source and evaluate equipment and process technology suppliers to meet project and process objectives.
• Collaborate with cross-functional teams (innovation, operations, maintenance, quality, etc.) to align designs with business goals.
• Troubleshoot process issues and provide technical guidance to resolve challenges.
• Ensure compliance with safety standards, health regulations, and internal procedures.
• Create and maintain technical documentation, including flow diagrams, reports, SOPs, and process specifications.
• Assess and continuously improve existing processes for cost-efficiency, reliability, and scalability.
• Contribute to the design, testing, and upgrading of equipment and process control systems.
• Serve as the process engineering resource for both Illinois manufacturing facilities—Broadview and Blue Island—supporting liquid, hot pour, and aerosol production lines.
• Lead continuous improvement (CI) initiatives across both IL sites using Lean and Six Sigma methodologies, including value stream mapping, kaizen events, and DMAIC-based projects.
• Develop, track, and report key performance indicators (KPIs) - such as OEE, yield, scrap/waste rates, downtime, and cost savings for liquid, hot pour, and aerosol processes to plant and executive leadership.
• Identify, scope, and lead cost-reduction and efficiency projects, quantifying savings and presenting results to site and company leadership.
• Partner with site leadership at Wireton and Parkes to standardize CI methodology, tools, and training across both facilities.

Skills

Lean Six Sigma

Project leadership

Cross-functional collaboration

Analytical skills

Communication skills

Problem solving

Travel readiness

Education

Bachelor's degree in chemical or mechanical engineering

Tools

Engineering design software

Job description

ADP, Inc. in Broadview, IL seeks a Process/Continuous Improvement Engineer to drive design, implementation and optimization of production processes across Broadview and Blue Island, supporting liquid, hot pour, and aerosol lines.

This hands-on role requires Lean and Six Sigma leadership, cross-functional collaboration, and a strong background in chemical or mechanical engineering with 3–5 years in regulated manufacturing.

Willingness to travel between IL sites is expected.