Senior Process Engineer

Location

• On-Site in Indian Head, MD

Role Overview

Core Responsibilities

• Process Assessment & Current-State Analysis Assess existing end-to-end manufacturing processes, including: · Manual, paper-based documentation · Batch movement of product across multiple on-site manufacturing buildings · Pre-, in-process, and post-operation safety inspections Required readings, sign-offs, and accountability steps at each phase
• Work directly with:
• Safety teams
• Quality personnel
• Machine operators and supervisors
• Operations and production leadership
• Observe and document how work is actually performed, not just how it is described in procedures Identify gaps, risks, inefficiencies, and compliance concerns in existing processes
• Stakeholder Engagement & Elicitation Elicit detailed process knowledge from non-technical stakeholders, including personnel who may be:
• Deep operational experience whose workflows are informal or not fully documented
• Skeptical or resistant to change
• Focused on safety, throughput, or compliance concerns
• Translate undocumented operational knowledge and experience-based workflows into clear, structured process documentation
• Build trust with operations teams by ensuring proposed changes:
• Improve safety
• Reduce burden
• Do not disrupt critical operations
• Compliance & Safety-Centered Process Design Ensure all process analysis and future-state designs:
• Preserve or enhance safety controls
• Support required compliance documentation and traceability
• Maintain clear accountability at every step of the process
• Understand and respect environments with:
• Strict procedural controls
• Required inspections and verifications
• Audit and review expectations
• Design processes that are defensible during internal and external review
• Digital Transformation & Future-State Design Lead the transition from paper-based processes to digital data capture, including:
• Tablet-based or workstation-based data entry
• Digital checklists, inspections, and sign-offs
• Structured capture of readings and measurements
• Define requirements for digital tools that:
• Reduce manual transcription
• Improve data accuracy and traceability
• Align with safety and compliance needs
• Ensure digital solutions reflect real operational workflows, not idealized models Collaborate with technical teams to translate process requirements into system requirements
• Documentation & Deliverables Produce clear, structured documentation, including:
• Current-state (“as-is”) process maps
• Gap and risk analyses
• Future-state (“to-be”) process definitions
• Requirements for digital workflows and data capture
• Clearly articulate:
• Why changes are necessary
• How safety and compliance are preserved or improved
• What operational impact is expected

Preferred Experience & Skills

• DoD manufacturing environment Energetics or ordnance environment Smart manufacturing environments Private 5G networks for data communication Functional understanding of Rockwell ControlLogix Allen Bradley PLCs, sensors (analog and digital), and HMIs Self-hosted (non-cloud) manufacturing systems, including 5G, IoT devices, and hard-wired sensors

Required Experience & Skills

• Proven experience as a Process Engineer in regulated, safety-critical manufacturing environments
• Strong background working with:
• Manual and paper-based compliance processes
• Batch manufacturing workflows
• Multi-building or campus-style operations
• Demonstrated ability to:
• Elicit requirements from non-technical stakeholders
• Navigate resistance to change
• Balance safety, compliance, and operational efficiency
• Experience supporting or leading digital transformation initiatives Excellent written and verbal communication skills Ability to operate independently in ambiguous environments Bachelor’s degree or equivalent military experience 5+ years in smart manufacturing Ability to document processes and requirements Ability to communicate well in writing and verbally with customers and stakeholders
• All employment opportunities are made without regard to age, race, creed, color, religion, sex, national origin, ancestry, disability status, veteran status, sexual orientation, gender identity or expression, genetic information, marital status or any other basis protected by law.
• Job Type: Full-time
• Work Location: In person