Senior Continuing Cost Engineer

About The Role

The Senior Cost Engineer is a specialized sustaining engineering role focused on reducing the cost of existing medical device products while maintaining regulatory compliance, quality, and customer performance. This role partners closely with Mechanical Engineering, Electrical Engineering, Supply Chain, Manufacturing, and Quality to identify, analyze, and execute cost-reduction initiatives across released products and legacy designs.

Unlike new product development roles, the Senior Cost Engineer operates primarily in a post-release environment, driving material, labor, tooling, and supplier cost improvements through structured engineering changes (ECOs) and cross-functional collaboration.

• Own and execute cost-reduction initiatives for medical device products, including BOM optimization, material substitutions, design simplification, and supplier changes.
• Identify high-impact cost drivers through BOM analysis, supplier spend reviews, labor studies, and field repair data.
• Lead engineering change activities (ECRs/ECOs) via Solid Works associated with cost reduction while ensuring compliance with ISO, IEC, FDA, and QMS requirements.
• Partner with Supply Chain, Quality and Manufacturing to evaluate alternate materials, processes, tooling strategies, and sourcing options.
• Collaborate with Mechanical and Electrical Design Engineers to assess technical feasibility and risk of proposed cost-down changes.
• Perform structured trade studies balancing cost, quality, risk, and manufacturability; document decisions and recommendations for leadership review.
• Support Design for Manufacturing (DFM), Design for Assembly (DFA), and Design for Cost (DFC) improvements on released products.
• Knowledge and experience with DFMEA, PFMEA, Root Cause Analysis (RCA) processes.
• Analyze warranty, service, and repair data to identify recurring cost opportunities and drive corrective actions.
• Coordinate validation, testing, and phased implementation of cost-driven changes to minimize production and field disruption.
• Track cost savings, implementation progress, and risk status; clearly communicate results to engineering and operations leadership.

• Bachelor’s degree in Mechanical Engineering or related engineering discipline; advanced degree preferred.
• 8+ years of engineering experience supporting manufactured products; medical device or regulated industry experience strongly preferred.
• Demonstrated experience leading cost-reduction, value engineering, or design-to-cost initiatives on released products.
• Proficiency with CAD tools (Solid Works preferred), PDM systems, BOM management, and issue-tracking tools such as Jira.
• Strong working knowledge of manufacturing processes such as injection molding, blow molding, machining, sheet metal, welding, wire routing, and assembly.
• Experience with supplier-facing engineering changes, alternate sourcing, and material/process substitutions.
• Working knowledge of ISO 13485, ISO 14971, applicable IEC standards, and FDA design control expectations.
• Ability to perform technical risk assessments and root cause analysis related to cost-driven changes.
• Strong analytical and financial acumen with the ability to quantify savings and articulate trade-offs.
• Excellent communication skills with the ability to influence across engineering, operations, and leadership.

• Experience applying Design for Cost (DFC) and value engineering methodologies.
• Familiarity with cost modeling, should-cost analysis, or parametric costing techniques.
• Experience supporting legacy products with incomplete or aging documentation.
• Previous experience working directly with contract manufacturers or global suppliers.
• Ability to mentor engineers on cost-aware design practices.

This role requires a pragmatic, systems-level thinker who is comfortable balancing cost objectives against quality, compliance, and operational risk. Success is measured by sustained, realized cost savings, not just identified opportunities. A successful candidate will be able to navigate relationships with internal and external stakeholders in Purchasing,…