Principal Process Safety Engineer (Manufacturing)

TL;DR

Principal Process Safety Engineer (Manufacturing): Designing and governing the global process safety framework to identify and control catastrophic hazards across manufacturing sites with an accent on risk reduction priorities and major hazard controls. Focus on leading process hazard reviews, consequence modelling, and ensuring systemic improvement of safety standards across regions.

Location: Newcastle, Australia. Must be based in Australia and hold full, unrestricted Australian working rights.

Company

Global leader in the design, manufacture, and supply of innovative wear products for the resources sector.

What you will do

• Lead and continuously improve the global Process Hazard Review framework, including standards, methodologies, and assurance processes.
• Define and maintain Maximum Credible Event frameworks and site-specific high-consequence scenario libraries.
• Conduct consequence modelling for risks including thermal radiation, overpressure, blast, toxic dispersion, and projectile hazards.
• Act as the technical authority for high-risk process hazard studies, safeguard strategies, and significant design changes.
• Govern high-hazard Management of Change (MoC) activity to ensure changes are technically justified and risk-assessed.
• Build process safety capability across regions through coaching, competency frameworks, and practitioner networks.

Requirements

• Extensive process safety experience in high-hazard industrial environments.
• Strong capability in process hazard analysis methods such as HAZOP, What-If, and FMEA.
• Ability to interpret PFDs, P&IDs, and process systems to translate technical information into hazard scenarios.
• Degree in Mechanical Engineering or an equivalent engineering discipline.
• Full, unrestricted Australian working rights and residency in Australia.

Nice to have

• Chartered or registered engineer status.
• Experience with Safety Case, MHF, or equivalent major hazard documentation.
• Experience in foundry, metallurgical processes, or molten metal hazards.
• Experience with LOPA and Bowtie methodologies.

Culture & Benefits

• Safety-first environment and mindset.
• Flexible work options.
• Competitive Total Reward Packages.
• Paid Parental Leave and Education assistance.
• Employee Assistance Program (EAP) for you and your family.
• Global and local recognition programs.

Hiring process

• Initial screening which may include a one-way video interview.
• Psychometric assessment.
• Pre-employment medical, including drug and alcohol testing.