Lead Process Engineer

Job Title: Lead Process Engineer

Job Description

The Lead Process Engineer oversees the operations and team members of a new polymer facility, ensuring a smooth transition from the existing plant while maintaining high standards of safety, quality, and efficiency. This role focuses on producing high-quality varnishes in a cost-effective manner, optimizing PLC-controlled processes, and driving continuous improvement across varnish production and maintenance activities. The Lead Process Engineer serves as a key interface with international counterparts, supports data-driven decision-making, and ensures full compliance with all applicable regulations.

Responsibilities

• Manage the day-to-day operations of the new polymer facility and lead the employees working in varnish production and maintenance.
• Lead and support the successful cutover from the present facility to the new polymer plant, minimizing disruption to production and quality.
• Ensure that varnishes are manufactured to consistently high quality standards while maintaining cost-effective and efficient operations in a safe working environment.
• Update, maintain, and ensure proper programming and functionality of PLC-controlled equipment to support reliable and optimized production processes.
• Recognize anomalies in the production process, interpret and analyze process data, and determine appropriate corrective and preventive actions.
• Help author and refine emergency procedures for backup or shutdown of equipment in the event of outages of power, compressed air, or other critical utilities.
• Interface directly with international counterparts to define and refine manufacturing KPIs, and extract and analyze data from SAP or similar systems to support these metrics.
• Collaborate closely with the EHS & Quality Systems leadership to ensure compliance with all applicable federal, state, and local regulations, and to promote a strong safety and environmental culture.
• Participate in safety inspections, review safety inspection reports, and manage the timely resolution of any identified discrepancies or non-conformances.
• Drive continuous improvement initiatives within varnish operations, using KPIs and data to identify opportunities to enhance efficiency, quality, and safety.
• Oversee the Maintenance Department responsible for maintaining plant buildings, utilities, and production equipment, ensuring high levels of reliability and uptime.
• Execute and improve preventative maintenance practices to reduce unplanned downtime and extend equipment life.
• Assess performance, skills, and training needs for varnish plant and maintenance employees, and support the development of training plans and coaching initiatives.
• Apply supply chain and ordering knowledge to support material availability, production scheduling, and efficient use of resources.
• Promote adherence to manufacturing safety protocols and foster a culture of continuous improvement and operational excellence.

Essential Skills

• 58 years of experience in a relevant engineering or process-focused role, ideally within chemical, polymer, or related manufacturing environments.
• Mechanical or Chemical Engineering background, with a strong understanding of process operations and equipment.
• Hands-on PLC programming experience, including updating, maintaining, and troubleshooting PLC-controlled equipment.
• Ability to lead and manage a team of approximately four employees, providing direction, coaching, and performance feedback.
• Strong understanding of manufacturing safety protocols and the ability to apply them in a plant environment.
• Experience in process analysis, problem-solving, and decision-making based on data and observed process behavior.
• Capability to collaborate effectively with EHS and Quality functions to maintain regulatory compliance and drive safety initiatives.
• Experience overseeing or working closely with maintenance functions and preventative maintenance programs.
• Ability to interpret and work with production data, including extracting information from systems such as SAP or similar ERP platforms.

Additional Skills & Qualifications

• Mechanical or Chemical Engineering degree or equivalent education and experience.
• background in chemical or polymer processes, varnish production, or similar industrial manufacturing.
• Experience with supply chain and ordering processes to support production planning and material availability.
• Familiarity with setting, tracking, and improving manufacturing KPIs and performance metrics.
• Experience authoring or contributing to emergency procedures and operational documentation.
• Strong communication skills to interface with international counterparts and cross-functional teams.
• Demonstrated ability to assess training needs and support skill development for plant and maintenance personnel.
• Continuous improvement mindset with experience implementing process enhancements in a production environment.

Work Environment

This is an onsite role based at a polymer and varnish manufacturing facility, operating primarily Monday through Friday. The position requires regular presence on the plant floor to oversee operations, equipment, and maintenance activities, with the option to work virtually or from home on Fridays when responsibilities allow. The environment includes working around PLC-controlled production equipment, process utilities, and maintenance operations, with a strong emphasis on safety, regulatory compliance, and preventative maintenance. Collaboration with cross-functional teams, including EHS, Quality, Maintenance, and international counterparts, is a regular part of the workday. The facility culture values meaningful impact, global collaboration, and continuous innovation, offering the opportunity to contribute to cutting-edge solutions that support a safer and more trustworthy world.

This is a Contract to Hire position based out of Springfield, VA.

The pay range for this position is $100000.00 - $130000.00/hr.

Individual compensation offered for this position within this range will depend on many factors, including qualifications, skills, relevant experience, job knowledge, geographic location, internal equity, and other pertinent job-related factors.

Eligibility requirements apply to some benefits and may depend on your job classification and length of employment. Benefits are subject to change and may be subject to specific elections, plan, or program terms. If eligible, the benefits available for this temporary role may include the following: Medical, dental & vision Critical Illness, Accident, and Hospital 401(k) Retirement Plan Pre-tax and Roth post-tax contributions available Life Insurance (Voluntary Life & AD&D for the employee and dependents) Short and long-term disability Health Spending Account (HSA) Transportation benefits Employee Assistance Program Time Off/Leave (PTO, Vacation or Sick Leave)

This is a Contract to Hire position based out of Springfield, VA.

This position is anticipated to close on Nov 12, 2026.

This is a fully onsite position in Springfield,VA.

About Actalent

Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 20,000 consultants and 5,000 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500. We are proud to be an Engineering News-Record (ENR) Top 500 Design Firm for our engineering design services and a ClearlyRated Best of Staffing® winner for both client and talent service.

The company is an equal opportunity employer and will consider all applications without regard to race, sex, age, color, religion, national origin, veteran status, disability, sexual orientation, gender identity, genetic information or any characteristic protected by law.

If you would like to request a reasonable accommodation, such as the modification or adjustment of the job application process or interviewing process due to a disability, please email for other accommodation options.

San Francisco Fair Chance Ordinance: Pursuant to the San Francisco Fair Chance Ordinance, for all positions located in the city and county of San Francisco, we will consider for employment qualified applicants with arrest and conviction records.

Massachusetts Lie Detector: It is unlawful in Massachusetts to require or administer a lie detector test as a condition of employment or continued employment. An employer who violates this law shall be subject to criminal penalties and civil liability.

Use of Artificial Intelligence (AI): We may use Artificial Intelligence (AI) to support parts of our hiring process, including sourcing, screening, and evaluating candidates. AI helps assess applications and qualifications, but final decisions are made by our hiring team. By applying, you acknowledge and agree that your application may be reviewed using AI tools.