Sr Manufacturing Engineer

About the Role

Starkey is seeking a Senior Manufacturing Engineer I at its global headquarters in Eden Prairie, MN. This position is responsible for ensuring product designs achieve business goals by implementing robust manufacturing processes and supporting continuous improvement. The ideal candidate will have a strong understanding of design or engineering to facilitate changes in new or current manufacturing processes, improving efficiencies. This role involves collaboration, mentoring, and building relationships to support best-in-class hearing aid manufacturing.

Responsibilities

• Fix potential problems during all product development phases, continuation, and end of life to support designs recognized as best-in-class in the hearing aid industry.
• Continually improve manufacturing processes for 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.
• Interface with R&D teams and contract manufacturers to develop and maintain positive interdepartmental 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 improvement efforts on existing manufacturing processes; implement new, fully tested processes.
• Partner with Design Engineering on new product development, participate in design reviews, establish manufacturing requirements, and coordinate 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 implement improvements.
• Identify and streamline improvements in the product development process.
• Pursue build and test automation where appropriate.
• Drive testing and troubleshooting of products to characterize devices.
• Generate test plans and procedures to characterize units.
• Coordinate product testing and report generation.
• Analyze process data, identify opportunities, and implement solutions.
• Optimize key manufacturing measures and report on them.
• Identify and drive opportunities to manage and reduce internal rework and material variance of Starkey’s hearing aids.
• Lead conference calls with manufacturing facilities to determine root cause and action items.
• Participate in solving product and process issues.
• Lead/facilitate Starkey and contract manufacturing Production PIPs (Product Improvement Programs) regularly.
• Provide production and recovery support.
• Initiate internal and some external product and process audits to drive improvements.
• Support manufacturing with failure analysis and corrective action implementation.
• Lead and support CAPA items using manufacturing tools such as DMAIC, DOE, Problem Analysis, SPC, and other problem-solving techniques.
• Provide yield expectations and analysis, time studies, and capacity.
• Lead and define manufacturing system design and maintenance strategies.
• Support and measure Manufacturing Technical support department performance and continuously improve it.
• Execute department performance scorecard and annual department objectives to drive strategic improvements.
• Mentor and provide guidance to junior engineers; meet regularly to discuss work direction and provide project guidance.
• Perform other duties/responsibilities as assigned.

Requirements

• Bachelor’s degree in manufacturing or mechanical engineering or equivalent work experience required.
• Six Sigma Greenbelt preferred.
• Six to ten years of manufacturing engineering in a product development environment required; hearing industry or medical device industry experience preferred.
• Knowledge of new product development systems and process validation required.
• Knowledge of relevant product development methods and best practices (e.g., DFMA, PFMEA, DFMEA, Lean PD, Agile development, DOE).
• Experience solving advanced technical problems and managing multiple projects simultaneously.

Skills

• Excellent analytical and problem-solving skills.
• Excellent people skills and ability to build relationships.
• Sufficient judgment to make reasonable business decisions concerning manufacturing issues with regard for both economic and quality aspects.
• Strong work ethic and a passion for managing people and processes.

Work Context

• Standard office conditions.
• Some travel (10-15%) expected to work directly with manufacturing sites.
• Equipment operation includes: measure scope/toolmakers microscope, computer and associated spreadsheet/word processing software, microscope, and acoustic test equipment.

Pay

The target rate for this position is between $93,940 to $119,187/year. Factors which may affect starting pay within this range may include geography/market, skills, education, experience, and other qualifications of the successful candidate. This position is eligible for a bonus based upon performance results, though there is no guarantee of payout.

Benefits

• Medical, dental, and vision insurance.
• 401(k) retirement plan with company match.
• Company-paid life and short-term disability insurance.
• Long-term disability insurance.
• Employee assistance plan.
• Hearing aid benefits.
• Paid Time Off, paid holidays, and paid floating holidays.
• Paid volunteer service day.
• Paid paternity and maternity leave.
• Tuition reimbursement.