Senior Process Engineer

Straffing AI; Knoxville (TN); On-site; USD 111,000 - 120,000; Full time

Job summary

Straffing AI is seeking an experienced Senior Process Engineer to lead and optimize manufacturing processes within a technical ceramic manufacturing facility. You will serve as a key technical owner for transitioning new processes from R&D into full-scale manufacturing, including process development, equipment specification, installation oversight, commissioning, validation, and production scale-up.

The ideal candidate brings a strong track record of developing, optimizing, troubleshooting, and

Qualifications

• 7+ years of process engineering experience in a manufacturing environment.
• Experience in developing, optimizing, troubleshooting, and scaling manufacturing processes.
• Strong experience with vendor and contractor management.
• Hands-on experience with FAT, SAT, commissioning, validation, and equipment implementation.
• Experience managing capital projects from concept to production implementation.
• Strong analytical and root-cause problem-solving skills.
• Proficiency using process data to identify issues and drive improvements.
• Excellent cross-functional communication skills.

Responsibilities

• Develop and optimize ceramic powder formulations and manufacturing processes to produce ready-to-press products.
• Develop best-method manufacturing processes for new products and materials.
• Lead commissioning activities, including FAT, SAT, and process validation.
• Manage capital projects from initial scoping to procurement, installation, commissioning, and implementation.
• Specify manufacturing equipment and serve as the technical interface with equipment manufacturers and suppliers.
• Lead process improvements that increase yield, throughput, efficiency, and overall manufacturing performance.
• Troubleshoot complex process and equipment issues using data-driven root-cause analysis.
• Lead engineering and continuous-improvement initiatives aligned with business-unit objectives.
• Monitor production metrics including output, downtime, scrap, yield, and efficiency.
• Develop, review, and update work instructions and quality-control documentation.

Skills

Process engineering

Vendor management

Root cause analysis

Project management

Data-driven decision making

Communication skills

Education

Bachelor’s degree in Engineering

Tools

FAT

SAT

Equipment implementation

Job description

Job Function: Manufacturing / Engineering

Compensation: $111,000 – $120,000

Job Type: Full-time

Experience Level: Mid-Senior

Experience Required: 7+ years

Education: Bachelor’s degree

Job Function: Manufacturing / Engineering

Industry: Mechanical or Industrial Engineering

Compensation: $111,000 – $120,000

Relocation Assistance: Not available

Visa Sponsorship: Not available

About the Role

We are seeking an experienced Senior Process Engineer to lead and optimize manufacturing processes within a technical ceramic manufacturing facility.

This role will serve as a key technical owner for transitioning new processes from R&D into full-scale manufacturing, including process development, equipment specification, installation oversight, commissioning, validation, and production scale-up.

The ideal candidate brings a strong track record of developing, optimizing, troubleshooting, and scaling manufacturing processes, along with hands-on experience managing vendors, contractors, capital projects, FAT/SAT activities, and process validation.

Experience in technical ceramics manufacturing is highly preferred, particularly expertise across ceramic powder processing and production.

What You’ll Do

• Develop and optimize ceramic powder formulations and manufacturing processes to produce ready-to-press products.
• Develop best-method manufacturing processes for new products and materials.
• Lead commissioning activities, including Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), and process validation.
• Manage capital projects from initial scoping and justification through equipment procurement, installation, commissioning, and implementation.
• Specify manufacturing equipment and serve as the technical interface with equipment manufacturers, raw material suppliers, contractors, and other vendors.
• Lead process improvements that increase yield, throughput, efficiency, and overall manufacturing performance.
• Troubleshoot complex process and equipment issues using structured, data-driven root cause analysis.
• Lead engineering and continuous-improvement initiatives aligned with business-unit objectives.
• Monitor key production metrics including output, downtime, scrap, yield, and efficiency.
• Develop, review, and update work instructions, quality-control documentation, and operator training materials.
• Collaborate closely with maintenance, quality, engineering, supply chain, operations, and other cross-functional teams.
• Ensure manufacturing processes and projects comply with applicable safety requirements.
• Perform detailed technical and operational analysis for executive review and clearly communicate findings to stakeholders at all organizational levels.
• Promote a strong safety culture and continuous-improvement mindset across manufacturing operations.

Required Qualifications

• Bachelor’s degree in Engineering or a related technical discipline.
• 7+ years of process engineering experience in a manufacturing environment.
• Demonstrated success developing, optimizing, troubleshooting, and scaling manufacturing processes.
• Strong experience with vendor and contractor management.
• Hands-on experience with FAT, SAT, commissioning, validation, and equipment implementation.
• Experience managing capital projects from concept/scoping through procurement, installation, commissioning, and production implementation.
• Strong analytical and root-cause problem-solving skills.
• Ability to use manufacturing and process data to identify issues, improve performance, and make technically sound recommendations.
• Strong project-management skills, including scope definition, budget management, scheduling, and contractor oversight.
• Excellent communication skills with the ability to work effectively across technical and non-technical teams.

Preferred Qualifications

• Experience in technical ceramics manufacturing.
• Experience with batching calculations, mixing, spray drying, calcining, and fine-particle milling.
• Experience with dry pressing, hot pressing, sintering, and ceramic machining.
• Master’s degree in Engineering or a related discipline.
• Experience transitioning processes from R&D or pilot scale into full-scale manufacturing.

Key Technical Areas

Ceramic Powder Processing | Process Development | Manufacturing Scale-Up | Batching & Mixing | Spray Drying | Calcining | Fine Particle Milling | Dry Pressing | Hot Pressing | Sintering | Ceramic Machining | FAT/SAT | Process Validation | Capital Projects | Equipment Commissioning | Root Cause Analysis | Continuous Improvement

What Success Looks Like

In this role, you will be expected to take ownership of manufacturing processes from development through production, ensuring that new processes and equipment are successfully scaled, validated, and optimized for reliable commercial manufacturing.

You will be a critical technical partner in improving yield, throughput, quality, safety, and operational efficiency, while helping the organization introduce new products and processes into production successfully.