Senior Process Engineer

Hydrograph USA INC; Austin (TX); On-site; USD 120,000 - 160,000; Full time

Job summary

HydroGraph USA INC seeks a Sr. Process Engineer to join the Advance Manufacturing team, connecting material properties, process behavior, and testing requirements for seamless production transfer.

You will lead NPI efforts, set process parameters, and mentor engineers while supporting new product launches and equipment decisions. Role requires deep experience in NPI, change control, and statistical methods, with hands-on plant-floor presence and collaboration across R&D, Manufacturing, and

Qualifications

• 10+ years of experience in process engineering or a related field.
• Experience with New Product Introduction (NPI) is required.
• Experience developing and approving process standards, test plans, and acceptance criteria.
• Experience identifying critical process parameters and using data to guide production decisions.
• Strong analytical and data-driven decision-making skills.
• Ability to work cross‑functionally with Manufacturing, R&D, and Quality.
• Experience mentoring or supporting less experienced engineers.
• Knowledge of SPC, DOE, and Lean Manufacturing.
• Strong knowledge of statistical analysis.

Responsibilities

• Develop and approve standards, processes, test plans, and documentation for new product introductions to production.
• Identify critical process parameters and operating limits; analyze data to support decisions and approve production parameters.
• Manage change control requests and determine testing levels for changes.
• Ensure readiness of FMEAs, DFMs, and RCFA analyses.
• Provide hands-on support and ideas to advance Advance Manufacturing goals.
• Assist in training production staff and ensure successful product transfers to production.
• Participate in design/development of new products, processes, and equipment.
• Mentor Process Engineers and cross-functional team members with engineering guidance.
• Collaborate cross‑functionally with R&D, Manufacturing, Quality to meet testing and material requirements.

Skills

Process engineering

NPI experience

Data analysis

Cross-functional comms

Mentoring

Statistical analysis

Lean manufacturing

DOE

SPC

Education

Bachelor’s degree in Engineering/Material Science/Chemistry

Tools

Visio

Job description

About HydroGraph

HydroGraph is a hyper-growth advanced materials company scaling pristine, high-performance graphene via its patented Hyperion detonation technology. With more than 70 active commercial projects, a growing global footprint, and industry-leading material quality (99.8% pure graphene), HydroGraph is building the next generation of engineered materials for coatings, composites, and energy storage.

Role Overview

We are seeking an experienced Sr. Process Engineer to join our Advance Manufacturing team. This role connects material properties, process behavior, and testing requirements to ensure new products and process changes are ready for production. The Sr. Process Engineer brings deep experience in new product introduction (NPI), works cross-functionally with R&D, Manufacturing, and Quality, and serves as a technical resource to less experienced engineers on the team. This role plays a key part in defining critical process parameters, testing standards, and change control decisions that protect product quality and consistency. Additionally, the Sr. Process Engineer contributes to mechanical system design and selection as needed.

Key Responsibilities

• Develop and approve standards, processes, test plans, and documentation required to ensure new product introductions are seamlessly handed off to production, balancing the needs of all stakeholders.
• Identify critical process parameters and operating limits required to ensure the process and product consistently meet requirements; gather and analyze data to support these decisions, and recommend or approve parameters for production.
• Manage change control requests and develop or analyze data to determine change control implementation decisions, including the level of testing required to approve changes.
• Ensure and participate in the technical completeness and readiness of FMEAs, DFMs, and RCFAs.
• Provide hands‑on support and ideas that advance the goals of Advance Manufacturing as well as the broader organization.
• Support the training and production readiness of new product launches, including helping train production technicians and operators, to ensure successful product transfers into production.
• Participate in the design and development of new products, processes, and equipment design/selection.
• Serve as a technical resource and mentor to Process Engineers and other team members, providing guidance based on engineering knowledge and analysis.
• Collaborate cross‑functionally with R&D, Manufacturing, Quality and other functions to ensure testing and material requirements are understood and met.

Qualifications

Required

• 10+ years of experience in process engineering or a related field.
• Previous experience in New Product Introduction (NPI) is required.
• Demonstrated experience developing and approving process standards, test plans, and acceptance criteria.
• Experience identifying critical process parameters and operating limits, and using data to guide production decisions.
• Strong analytical and data-driven decision-making skills.
• Ability to work cross‑functionally and communicate effectively with various teams such as (but not limited to) Manufacturing, R&D, and Quality.
• Experience mentoring or supporting less experienced engineers.
• Knowledge of Statistical Process Control (SPC), Design of Experiments (DOE), background in Lean Manufacturing.
• Strong knowledge of statistical analysis.

Preferred

• Bachelor's degree in Engineering, Material Science, or Chemistry.
• Background in chemical processing, material development, or a related industry (potentially including food production) may be beneficial.
• Green or Black Belt certification.
• Experience with Visio or similar process‑mapping/documentation tools.

Key Competencies

• Leadership and team motivation
• Accountability and ownership mindset
• Strategic thinking and business acumen
• Stakeholder management and relationship building
• Conflict resolution and negotiation
• Adaptability and flexibility in dynamic environments
• Decision‑making under uncertainty
• Attention to detail and quality focus
• Customer service orientation
• Emotional intelligence and active listening
• Critical thinking and creative problem‑solving

Work Environment

This role operates in an active chemical/process manufacturing environment and requires regular presence on the plant floor. The engineer will be exposed to industrial equipment, chemical agents, and process systems, and must adhere to all applicable safety protocols at all times.

• Environment: Indoor and outdoor process/chemical plant settings; exposure to heat, noise, fumes, and moving machinery is expected. Must be able to occasionally work outdoors in varying weather conditions to operate valves and manage chemical feedstock supply lines, following all chemical handling and site safety protocols.
• Physical Requirements: Must be able to stand and walk for extended periods throughout the shift. Frequent lifting and carrying of equipment, tools, or materials up to 20 lbs; occasional lifting up to 50 lbs with assistance.
• Working at Heights: Must be able to occasionally work at elevations up to 15 ft when troubleshooting and maintaining process equipment, utilizing ladders, platforms, scissor lift or elevated walkways in accordance with site safety requirements.
• Personal Protective Equipment (PPE): Use of PPE is mandatory in designated areas, including but not limited to safety glasses, hard hat, steel‑toed boots, hearing protection, respiratory protection (breathing mask/respirator) when working in areas with chemical exposure or poor ventilation, and fall protection equipment (full‑body harness and lanyard) when working at elevated heights.
• Schedule: Standard business hours, Monday through Friday. Occasional weekend or off‑hours work may be required to support planned maintenance, shutdowns, startups, or urgent production challenges.
• Travel: May require occasional travel to other production facilities, client locations, or vendor facilities.

Why Join HydroGraph

• Lead the core scientific engine of one of the fastest‑growing graphene companies in the world.
• Shape a next‑generation materials platform used across aerospace, energy, infrastructure, consumer goods, and defense.
• Work directly with global partners and world‑class advisors (GEIC, OEMs, DoD).
• Competitive compensation, and career advancement as the company scales.