Sr Manufacturing Engineer

Overview

Sr Manufacturing Engineer I – Starkey, Eden Prairie, MN. This position focuses on designing and implementing robust manufacturing processes to meet business goals, improve manufacturing efficiencies, and support continuous improvement across manufacturing operations. Strong communication, technical drive, persistence, and team-building skills are required to maintain a quality product. The role includes collaboration with Design Engineering, Quality Engineering, R&D, and contract manufacturers, and mentoring junior engineers.

• Continually improve the manufacturing processes of our custom, standard, and accessory products.
• Lead PFMEA efforts during product development to reduce process risks.
• Represent Manufacturing Engineering (voice of manufacturing) to other development teams within R&D and Contract manufacturers.
• Act as technical manufacturing lead at the program level and interface with R&D teams to develop and maintain positive interdepartmental collaboration.
• Interface with contract manufacturers to develop and maintain positive collaboration; provide recommendations regarding contract manufacturing capabilities.
• Support and provide input for DFM improvements through Program/Project charters and system requirements specifications.
• Lead and drive improvements on existing manufacturing processes, justifying and implementing new fully tested processes.
• Partner with Design Engineering on new product development; participate in design reviews, establish manufacturing requirements, and coordinate needed testing or device builds.
• Partner with Quality Engineering to identify and implement ongoing quality improvements; qualify and validate new and improved processes, fixtures, equipment, and technology for manufacturability.
• Review manufacturing processes for inefficiencies and identify opportunities to streamline the product development process; pursue build and test automation where appropriate.
• Drive testing and troubleshooting of products to characterize the device; generate test plans and procedures; coordinate product testing and report generation; analyze process data; identify opportunities and implement solutions.
• Optimize key manufacturing measures; organize and report on metrics; identify opportunities to reduce internal rework and material variance; lead conference calls with facilities to determine root causes and action items.
• Participate in solving product and process issues; lead or facilitate Product Improvement Programs (PIPs) with Starkey and contract manufacturing partners; provide production and recovery support.
• Initiate internal and external product and process audits to drive improvements; support manufacturing with failure analysis and corrective action implementation; lead and support CAPA items using DMAIC, DOE, problem analysis, SPC, and other problem-solving techniques.
• Provide yield expectations, time studies, and capacity planning; define manufacturing system design and maintenance strategies.
• Provide support and measure Manufacturing Technical Support department performance; execute department performance scorecards and annual objectives.
• Mentor and provide guidance to junior engineers; meet regularly to discuss work direction and project progress.

Education, Certification and Experience

• Bachelor’s degree in manufacturing or mechanical engineering or equivalent work experience required.
• Six Sigma Green Belt preferred.
• Six to ten years of manufacturing engineering in a product development environment required; hearing industry or medical device experience preferred.

Knowledge / Technical Requirements

• Knowledge of new product development systems and process validation.
• Familiarity with DFMA, PFMEA, DFMEA, Lean PD, Agile development, DOE, and related methods.
• Experience solving advanced technical problems and managing multiple projects simultaneously.

Competencies, Skills & Abilities

• Excellent analytical and problem-solving skills; strong people skills.
• Judgment to make reasonable manufacturing decisions balancing economic and quality considerations.
• Strong work ethic with passion for managing people and processes.

Working Conditions

• Standard…