Senior Process Engineer - Assembly
Job Summary
Process Engineering is responsible for developing new assembly and sub-assembly manufacturing processes for electromechanical products, from manufacturability review and quoting support through first article build, process validation, and release to Manufacturing Engineering. Process Engineering partners with Manufacturing Engineering, Quality, and customers to ensure new processes are producible, repeatable, and fully documented before transfer to production. This job class has four experience levels: Process Engineer I, Process Engineer II, Senior Manufacturing Process Engineer, and Principal Manufacturing Process Engineer.
Essential Duties and Responsibilities
Review customer prints, BOMs, and specifications for assembly feasibility and build sequence; identify sub-assembly breakdown and flag Design for Assembly (DFA) issues to customers and Sales
Provide build time, tooling, and fixture cost estimates to support quoting activities
Define assembly sequence and station/line layout from sub-assembly stations through final assembly
Design or source fixtures, jigs, and torque/fastening tools; set and validate torque specs, adhesive/sealant parameters, and press-fit forces
Define kitting requirements per station and procure prototype/first article hardware and sub-assembly components
Plan and run first article sub-assembly and final assembly builds; verify integration, fit, function, and torque retention
Lead root cause analysis and containment on issues found during pilot builds
Complete first article inspection (FAI) reports and customer approval packages; validate repeatability of critical joins
Author work instructions per station, including torque/fastener callouts; complete PFMEAs and control plans for each sub-assembly and integration step
Define operator training/certification requirements per station
Assemble the process handoff package and lead the formal handoff review with Manufacturing Engineering; remain available as an escalation point during the post-handoff support window
Follow and comply with all safety and work rules and regulations
Independently own moderate-to-high complexity design transfers end-to-end, from DFA review and quoting support through first article, validation, and handoff
Lead process development, sequencing, and fixture/tooling design for multi-station sub-assembly and final assembly builds
Lead process capability studies (e.g., Cpk) on critical joins; support IQ/OQ activities where required
Author and review PFMEAs, control plans, and validation protocols
Lead root cause investigation and containment on pilot and early-production issues, coordinating with Quality and Manufacturing Engineering
Represent Process Engineering in customer design reviews and first article approvals
Identify and lead moderate-scope continuous improvement and cost-reduction initiatives within assigned programs
Contribute to departmental templates and best practices for work instructions, PFMEA methodology, and validation protocols
Mentor Process Engineer I team members
Serve as technical lead for assembly process development on assigned programs; apply and help develop engineering standards for fixtures, torque/fastening control, work instructions, PFMEAs, and control plans
Own and continuously improve the NPD-to-Production handoff process, including handoff package requirements, joint walkthroughs, and the post-handoff support window
Lead manufacturability reviews and drive DFA feedback to customers and Sales; develop and review build time, tooling, fixture, and capital cost estimates
Lead process validation (IQ/OQ/PQ or equivalent) for new and changed processes
Author and approve work instructions, DHR documents, PFMEAs, and process validations
Present process plans, validation results, and corrective actions to customers and internal leadership
Support customer and regulatory audits as the process subject-matter expert
Prioritize and coordinate engineering workload across multiple programs with the Process Engineering Manager
Review designs, documentation, and validation work completed by Process Engineer I and II team members
Mentor Process Engineer I and II and Manufacturing Engineer team members
An individual in this position must be able to successfully perform the essential duties and responsibilities listed above. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions of this position . The above list reflects the general details necessary to describe the principle and essential functions of the position and shall not be construed as the only duties that may be assigned for the position.
Experience and Knowledge
7 to 15 years of manufacturing or process engineering experience in mechanical/electromechanical assembly, including at least 3 years launching new assembly processes
Led new process introductions from quote through first article, validation, and release to production
Designed or specified assembly fixtures and tooling, and set torque/fastening, adhesive/sealant, and press-fit parameters for production
Authored and maintained PFMEAs, control plans, and work instructions, including engineering change control and re-qualification on released processes
Led root cause and corrective action investigations (8D, 5 Why, fishbone) that delivered measurable gains in yield, scrap, or cycle time
Completed process validation (IQ/OQ/PQ) and FAI in an ISO 13485, ISO 9001, or similarly regulated environment
Mentored engineers and trained or certified production operators
Proficient in SolidWorks or equivalent CAD
Lean or Six Sigma certification (Green Belt or higher) and medical device assembly experience preferred
Note: Years of Experience is a guideline. Promotion depends primarily on demonstrated performance, knowledge, and capability.
Education
Bachelor's degree in Mechanical, Manufacturing, Industrial, or Biomedical Engineering, or a related technical field
Degree requirement may be waived with sufficient engineering-related work experience
Physical and Mental Demands
Frequent standing, walking, and sitting in office and production environments
Occasional bending, reaching, and light lifting (up to 40 lbs., if applicable)
Visual acuity to review drawings and data and observe assembly processes, with color perception required
High level of analytical thinking and problem-solving to evaluate build processes and identify root causes
Ability to manage multiple programs simultaneously with shifting priorities
High attention to detail with strong organizational skills
Effective communication skills, including presenting to customers, production teams, and less experienced engineers
Ability to receive and provide instructions in a positive manner
The mental and physical requirements described here are representative of those that must be met by an individual to successfully perform the essential functions of this position.
Work Environment
Office environment with frequent need to be on the production floor supporting builds and pilot runs
In the production facility, noise level is moderate to loud, and not all areas are climate controlled
The work environment characteristics described here are representative of those an individual encounters while performing the essential functions of this position .