Manufacturing Engineer

Hologic is one of the world’s most innovative medical technology companies and a global champion of women’s health. We advance diagnostic, detection, and surgical solutions that respond to an increasingly complex and demanding global healthcare environment. What powers our growth is also what differentiates us: the exceptional, clinically proven ability of our products to detect, diagnose, and treat illnesses and other health conditions earlier and better.

The Senior Level Metal Materials Engineer will be an essential team member supporting internal manufacturing by managing and validating projects, often with suppliers, for new custom metal materials, fabricated components, and related manufacturing processes. Projects begin at design concept and conclude with production acceptance. Responsibilities include supplier process development, technical evaluation, testing, statistical analysis, qualification, and ongoing process improvement. This position also involves sustaining product support to ensure quality products, continuity of supply, and cost savings initiatives.

The role incorporates various engineering disciplines, including Manufacturing Engineering, Mechanical Engineering, Materials Engineering, and Supplier Quality Engineering.

• Manage metal raw materials, fabricated components, and assemblies, including finished and semi-finished forms
• Lead initiatives that may involve sheet, bar, tube, foil, wire, or custom alloy supply materials
• Lead initiatives that may involve machined, stamped, formed, welded, or finished parts
• Lead technical evaluation and qualification of new and existing metal suppliers, including process capability, control strategies, and manufacturing readiness
• Review supplier process flow, PFMEA, control plans, inspection methods, and validation packages to ensure robust and scalable production
• Support first article inspection, process qualification, and production acceptance activities for supplier-manufactured metal materials and components
• Lead materials failure and defect analysis, including corrosion, cracking, burrs, contamination, hardness issues, dimensional drift, cosmetic defects that impact function, and surface finish problems
• Apply mechanical understanding of custom manufacturing systems and metal component fabrication processes and their impact on performance
• Develop inspection and measurement techniques, including fixtures, gauges, and metrology approaches for dimensional, surface, and functional verification
• Continuously improve internal and external supplier processes to reduce the time to market, enhance product quality, and decrease costs

• Support the design transfer process from R&D to Operations, which may include defining material requirements, qualifying metal raw materials and assemblies, and establishing supplier manufacturing methods
• Provide Design for Manufacturing feedback based on concepts, drawings, and prototype components to achieve robust and consistent manufacturing processes
• Provide material and process alternatives based on application requirements, including alloy selection, forming method, machining approach, joining method, surface finish, corrosion resistance, and cleanliness requirements
• Collaborate with suppliers on prototype development, manufacturability assessments, and process readiness for scale-up

• Support complex cross-functional investigations
• Perform root cause analysis and recommend corrective actions for non-conforming events or manufacturing concerns utilizing risk-based approach methods
• Participate in ideation activities, cause and effect analysis, process variables mapping, and pFMEAs
• Initiate and/or review change orders related to suppliers, including collaborating with appropriate departments and personnel
• Actively manage tooling, fixtures, and process maintenance with suppliers and monitor performance trends
• Support supplier quality and process improvements related to dimensional variation, surface condition, corrosion, fit, function, and long-term process capability
• Establishes and maintains productive working relationships
• Identifies…