- Actively support NPI by working hands-on on the production floor to troubleshoot issues, stabilize yields, and drive smooth transitions from development to full-scale manufacturing.
- Collaborate with Development and R&D Engineers to execute effective design transfer, process characterization, and ramp plans.
- Conduct process capability studies and apply DOE, SPC, and data-driven analysis to draw conclusions, implement improvements, and sustain gains.
- Develop standard work, process controls, and monitoring methods to reduce variability across operators, materials, equipment, and workflows.
- Investigate process deviations and failures; perform structured root cause analysis (5-Why, Fishbone, FMEA) and implement robust corrective and preventive actions (CAPA).
- Proactively identify opportunities for improvement and challenge assumptions constructively to drive better outcomes.
- Create and execute IQ/OQ/PQ and related verification and validation protocols, analyze results, and generate complete documentation and reports.
- Ensure compliance with design control, validation, documentation, and change-control policies (FDA, ISO, cGMP, QMS).
- Create and maintain clear, complete manufacturing documentation (MPIs, LHRs, WIs, forms, checklists) that reflect current practices and controls.
- Train and guide technicians and assemblers; drive best practices and foster a culture of safety, quality, and continuous improvement.
- Contribute to design-for-manufacturability (DFM), cost reduction, quality improvement, and automation initiatives.
- Cultivate a mindset of ownership and innovation, where individuals actively seek out challenges and collaborate across teams to solve them
- 3–7 years of hands-on experience in a manufacturing environment, with a proven track record in process development, optimization, and validation.
- Extensive experience with process capability studies, FMEA, PPK, GR&R, SPC, and process development/validation.
- Knowledge and experience with plastic injection molding as well as semi-automated and fully automated machines/processes
- Proven ability to perform statistical data analysis and implement improvement plans using DOE and other methods.
- Strong analytical and problem-solving skills including but not limited to DOE, and statistical data analysis
- Knowledge of material science and polymer chemistry
- Diverse background in process characterization and optimization in a manufacturing environment.
- Experience with FDA regulations and ISO, cGMP, and QMS standards.
- Experience with Statistical Software tools such as Minitab or JMP
- Familiarity with cleaning and sterilization processes
- Working knowledge of SolidWorks
- Bachelor’s Degree in Mechanical, Chemical, Manufacturing, or a related engineering field.
- Relevant certifications as pertains to the position (e.g., Six Sigma, Lean Manufacturing, etc.) is a plus.
- Proficiency in Microsoft Excel, Microsoft Word, and other engineering software tools.
- Familiarity with metrology tools such as CMM, Micro-Vu, SEM, etc. is a plus.
- The employee is regularly required to stand, walk, and sit for extended periods during the performance of job duties.
- Must be able to physically be present on-site to perform the required tasks.
Pay Range: $137,000 – $160,000 per year
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