Senior Process Engineer

Actalent; Pleasant Prairie (WI); On-site; USD 90,000 - 120,000; Full time

Job summary

Join a leading engineering services company as a Senior Process Engineer in Pleasant Prairie, WI. In this role, you'll drive technological and process improvements, manage projects, and collaborate across departments to enhance production efficiency. The ideal candidate will have extensive experience in polymer extrusion, particularly in the medical field, and possess strong project management skills. This position offers a competitive salary and comprehensive benefits package, including medical, dental, and 401(k) options.

Benefits

Medical, dental, and vision insurance

401(k) with pre-tax and Roth options

Life Insurance

Disability insurance

HSA

Transportation benefits

Employee Assistance Program

PTO and leave benefits

Qualifications

• 10+ years of industry experience in polymer extrusion and converting preferred.

Responsibilities

• Evaluate, implement, and monitor processes for flexible packaging products.
• Drive global projects to achieve best-in-class technology.
• Manage validation efforts and translate customer needs into measurable CTQs.

Skills

Project Management

Lean Six Sigma

Statistical Analysis

Problem Solving

Education

Bachelor’s degree in engineering

Job description

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Job Description

Drives technological improvement activities and process improvement activities. Creates and implements new products/processes, improves productivity, reduces customer complaints, and reduces costs. Coordinates implementation of new capital manufacturing equipment and processes to optimize production and increase capacity. Drives improvements to reduce scrap, raise quality levels, and optimize processes. This individual will work extensively in their Class 7 clean room, performing validations and setting up processes. Ideal candidate will have extrusion and medical tubing experience.

Responsibilities

• Evaluate, implement, and monitor processes and operating systems for the manufacture of flexible packaging products.
• Drive global projects, including identifying and sourcing capital needs to achieve best-in-class technology and processing.
• Perform cost improvement projects and quality improvement projects to support manufacturing goals that positively impact and reduce COGS.
• Define and manage project activities for the commercial release of new products and manufacturing processes, ensuring sustainable, efficient, and reproducible operations.
• Collaborate with site operations leadership to identify and resolve technical challenges and support commercial solutions.
• Act as a conduit to the commercial team for product requirements, quotes, cost structures, and milestones.
• Manage validation efforts, including scoping master validation plans and executing complex validations with documented protocols and reports.
• Translate customer needs into measurable CTQs for project scoping, progress reporting, and actionable plans.
• Apply risk management practices to development processes by identifying hazards, evaluating risks, and monitoring controls.
• Collaborate and communicate effectively across departments, using strong presentation skills to connect technical concepts to business outcomes.

Essential Skills

• Expertise in extrusion, polymer extrusion, and tubing.
• Experience with polyolefin materials and material recommendations based on application.
• Understanding of flexographic printing processes.
• Proficiency in Project Management tools, Design of Experiments, Lean Six Sigma, and Statistical Analysis.
• Bachelor’s degree in engineering or related field.
• 10+ years of industry experience in polymer extrusion and converting preferred.

Additional Skills & Qualifications

• Experience with medical equipment and devices.
• Resourcefulness and innovation in project execution.
• Effective communication skills for project expectations.
• Strong problem-solving skills for error identification and research.

Work Environment

This role involves extensive work in a Class 7 clean room, performing validations and process setups. The environment is fast-paced, requiring collaboration across departments, with potential use of specialized equipment and adherence to strict quality and safety standards. Work hours and shifts will be discussed during the interview.

Pay and Benefits

The pay range is $90,000 - $120,000 annually.

Requirements

Eligibility for benefits may depend on job classification and employment length. Benefits may include:

• Medical, dental, and vision insurance
• Critical Illness, Accident, Hospital coverage
• 401(k) with pre-tax and Roth options
• Life Insurance
• Disability insurance
• HSA
• Transportation benefits
• Employee Assistance Program
• PTO and leave benefits

Workplace Type

Fully onsite in Pleasant Prairie, WI.

Application Deadline

May 23, 2025.

About Actalent

Actalent is a global leader in engineering and sciences services, supporting innovation and speed to market for Fortune 500 companies with a network of nearly 30,000 consultants worldwide.