Senior Process Engineer

Upcoresolutions; Knoxville (TN); On-site; USD 85,000 - 120,000; Full time

Job summary

Upcoresolutions in Knoxville, TN seeks a Senior Process Engineer to lead the transfer of ceramic process tech from R&D to full-scale manufacturing. You will specify equipment, oversee installation, and drive validation and scale-up while partnering with cross‑functional teams to meet safety and efficiency goals.

The role requires 7+ years in process engineering within a manufacturing setting, with strong background in batching, spray-drying, calcining, and ceramic processing.

Qualifications

• Minimum 7 years in a process engineering role in a manufacturing environment.
• Preferred experience in a technical ceramic manufacturing environment.
• Experience with batching calculations, mixing, spray-drying, calcining, and fine particle milling.
• Additional experience in dry-pressing, hot-pressing, sintering, and ceramic machining processes is a strong plus.

Responsibilities

• Work safely and promote a safety mindset.
• Lead transfer of new processes from R&D to full-scale manufacturing, including equipment specification and installation oversight.
• Drive commissioning activities (FAT, SAT) and process validation.
• Develop and optimize manufacturing processes for new products/materials.
• Manage capital projects from scoping to installation and startup.
• Analyze performance metrics and deliver yield/throughput improvements.
• Create and update work instructions, QC docs, and operator training.

Skills

Analytical thinking

Project management

Communication

Data analysis

Problem solving

Education

Bachelor's degree in Engineering

Job description

Our client is seeking - Senior Process Engineer, responsible for establishing, maintaining and optimizing process engineering operations within a technical ceramic manufacturing facility. This role serves as the primary owner for transitioning new processes from R&D into full-scale manufacturing, including specifying equipment, oversight of equipment installation, commissioning, validation, and process scale-up activities. The position partners cross-functionally to execute engineering initiatives aligned with business unit strategies, while driving operational excellence, safety, and continuous improvement.

Roles & Responsibilities: including but not limited to

• Work safely and encourage a safety mindset
• Ceramic powder formulation and process development to produce ready-to-press products
• Lead commissioning activities, including Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), and process validation.
• Develop best method manufacturing processes for new products and materials
• Manage capital projects from scoping and justification, through equipment procurement and installation.
• Responsible for process improvements that deliver yield or throughput gains.
• Lead problem solving activities for complex process and equipment related issues.
• Develop, review, and update work instructions, quality control documentation, and operator training as required.
• Serve as the primary interface with manufacturers and vendors that supply raw materials and process equipment to the company, from specification setting through implementation, into manufacturing and acceptance testing.
• Ensure compliance with safety requirements
• Perform detailed analysis for executive review and effectively communicate findings across all organizational levels.
• Monitor production standards and performance metrics including output, downtime, scrap, and efficiency.
• Collaborate with maintenance, quality, engineering, and supply chain teams to optimize production processes.

Education

• Bachelor's degree in Engineering or related discipline. Master's degree a plus

Experience

• Minimum 7 years in a process engineering role in a manufacturing environment.
• Preferred experience in a technical ceramic manufacturing environment
• Particular expertise in batching calculations, mixing, spray-drying, calcining, and fine particle milling.
• Additional experience in dry-pressing, hot-pressing, sintering, and ceramic machining processes considered a strong plus.

Functional/Technical Knowledge, Skills & Abilities

• Analytical/Critical Thinking - Identify root causes, implement effective solutions, improve processes, mentor others in data-driven strategies, and foster innovation through critical thinking and self-reflection.
• Business Acumen - Align individual and/or departmental goals with organizational strategy, while collaborating cross-functionally to improve operational metrics.
• Communication – Effectively communicate technical and strategic information across all levels of the organization, while remaining responsive to feedback and stakeholder needs.
• Data Analysis – Utilize a data-driven approach to product development with a key focus on the powder production aspect, while mentoring others and effectively communicating insights to leadership.
• Project Management - Independently lead multi-phase projects, including scope definition, budget management, schedule control, and contractor oversight.