Sr. Process Engineer

Who we are

At Sonova, we envision a world where everyone can enjoy the delight of hearing. This vision inspires us and fuels our commitment to developing innovative solutions that improve hearing health and human connection - from personal audio devices and wireless communication systems to hearing aids and cochlear implants. We're dedicated to providing outstanding customer experiences through our global audiological care services, ensuring that everyone has the opportunity to engage fully with the world around them.

Guided by a culture of continuous improvement that fosters resilience and self-motivation, our team is united by a shared commitment to excellence and a deep sense of pride in our work, each of us playing a vital role in creating meaningful change,

Here you'll find a diverse range of opportunities that span both consumer and medical solutions and the freedom to shape your career while making an impact on the lives of others. Join us in our mission to create a more connected world, where every voice is heard and every story matters.

Aurora (IL), United States

Sr. Process Engineer

Aurora, IL Sr. Process Engineer About the role

We are seeking a Sr. Process Engineer with strong experience leading automation initiatives in manufacturing and distribution environments. This role is responsible for identifying automation opportunities, developing ROI cases, partnering with vendors, and taking solutions from concept through installation, validation, and production ramp-up. You will work cross-functionally to improve efficiency, quality, safety, and scalability across North American operations.

• Process Engineering

  • Identify and analyze process bottlenecks, inefficiencies, and sources of waste using Lean, Six Sigma, or similar methodologies.

  • Drive continuous improvement initiatives to enhance yield, cycle time, and process reliability.

  • Implement data-driven solutions by leveraging process metrics, trend analysis, and root cause analysis (RCA).

  • Develop and standardize process documentation, procedures, and best practices to ensure scalability and knowledge transfer.

  • Validate processes as required and ensure adherence to medical device regulations and Sonova's change management process.

  • Foster a culture of engineering excellence and collaboration across manufacturing and engineering teams.

  • Participate in Kaizen events and use Sonova
    
    X tools to drive continuous improvement initiatives.

  Process Development & Automation

  • Design and implement automated solutions for material handling, sorting, packaging, and storage (e.g., conveyors, robotics, AS/RS systems).

  • Evaluate and integrate control systems such as PLCs, SCADA, and warehouse management systems (WMS).

  • Collaborate with vendors and IT teams to ensure seamless integration of automation equipment and software (e.g., SAP).

  • Define process parameters, build process flow diagrams (PFDs), and establish standard operating procedures (SOPs).

  • Lead proof-of-concept trials, prototyping, Design of Experiments (DOE), scale-up, and commissioning of new automated systems.

  • Develop and maintain an automation playbook from concept through FAT, SAT, and validation phases.

  • Deploy automated systems developed by global teams across North American sites.

  Plant Layout & Project Management

  • Develop and optimize plant and warehouse layouts using AutoCAD or similar tools to improve material flow, space utilization, and efficiency.

  • Conduct time, motion, and space studies to support reconfiguration of work areas and equipment placement.

  • Ensure compliance with safety, ergonomic, and regulatory standards in layout designs.

  • Lead end-to-end execution of engineering projects, including planning, scope, budgets, and timelines.

  • Collaborate with internal teams and external vendors to ensure on-time, within-scope delivery of initiatives.

• Bachelor's degree in Mechanical Engineering or Automation (Master's preferred)

• 4-6 years of experience in Process Engineering, Automation, Robotics, and Scale-up

• Experience in manufacturing or warehouse environments preferred

• Proficient in AutoCAD, Solid Works, Minitab, and Microsoft Office applications

• Familiarity with SAP or other ERP systems

• Strong analytical, organizational, and project management skills

• Excellent communication, presentation, and interpersonal abilities

• Team player with conflict management and influencing skills

• Flexible and willing to travel up to 30%

• Medical, dental and vision coverage*
• Health Savings, Health Reimbursement, Flexible Spending/Dependent Care Accounts
• Tele Health options
• 401k plan with company match*
• Company paid life/ad&d insurance
• Short/Long-Term Disability coverage (STD/LTD)
• Accident/Hospital Indemnity coverage
• Legal/ Assistance
• PTO, floating Diversity Day, & paid holidays*
• Paid parental bonding leave
• Employee Assistance Program (24/7 mental health support, 5 paid counseling sessions)
• Internal career growth opportunities
• Tuition reimbursement
• Hearing aid discount for employees and family
• Internal social recognition platform

* Plan…