Sr Manufacturing Design Engineer I - Onsite

Starkey is hiring a Sr. Manufacturing Design Engineer I at our global headquarters in Eden Prairie, MN ! Join our Design Engineering team and help bring cutting-edge hearing technology to life. In this role, you’ll ensure products are designed for efficient, cost-effective manufacturing—reducing part count, complexity, and assembly time without sacrificing quality. Experience with PCBA and micro-electronics is a huge plus. If you have strong technical skills, a passion for process improvement, and love solving problems before they happen, apply now and be part of something that truly improves lives.

Starkey is a world leader in the manufacturing and distribution of advanced hearing technologies. We are in the business of connecting people and changing lives. Our teams come to work each day focused on ensuring people everywhere have the products and services they need to hear better and live better. Founded in 1967 by Bill Austin, Starkey is known for our cutting-edge hearing health innovations, industry-leading research and development, and not being afraid to push the edge of what’s possible. We are headquartered in Eden Prairie, Minnesota, have over 5,000 employees in 29 facilities across the globe, and do business in more than 100 markets worldwide.

Watch this video to see more of what sets Starkey apart.

This position is responsible for ensuring product designs are easy and economical to manufacture and achieving business goals, analyzing product design and manufacturing process development. Must have a vision of designing or engineering a product in order to facilitate the new and current manufacturing processes to reduce manufacturing costs, time to assemble, final BOM cost, and reduce part count. Must have a strong communication skills, technical drive, persistence and team building skills while maintaining a quality product. Fix potential problems during the design phase and to support the development of designs that are recognized as best- in-class in the hearing aid industry.

JOB RESPONSIBILITIES/RESULTS

Continually improve the manufacturing processes of our custom, standard and accessory products.

• Lead and drive PFMEA efforts during product development to reduce process risks.
• Represent Manufacturing Engineering (voice of design for manufacturing excellence) on product development teams within R&D and Contract manufacturers.
• Act as technical design for manufacturing lead at the project level for final aid assembly
• Interface with R&D teams while developing and maintaining positive interdepartmental collaboration.
• Support and provide input for DFM improvements through Program / Project charters and system requirements specifications
• Partner with Design Engineering on new product development. Participate in design reviews, establish manufacturing requirements, and coordinate needed testing or device builds.

Improve existing manufacturing processes that are justified through continuation engineering projects

• Identify and drive opportunities to reduce the 12-week TRR (Total Return Rate) of Starkey’s hearing aids.

Participate in solving product and process issues.

• Production PIPs (Product Improvement Programs) Support
• Production and operation fulfilment support.

Maintain and provide updates for DFx process to ensure process deliverables are completed.

• Ensure DFM checklist is updated in accordance with project timelines
• Provide status during Hardware/E-NPI gate reviews

DFMA Support for E-NPI Initiatives.

• Use the DFA software to model E-NPI products. Use Outputs of models to influence product design and assembly requirements.
• Track product and process changes and resulting impact on cycle time and assembly cost. Update models to capture incremental changes and final correlation after product launch
• Use DFM and DFA methodology to reduce material cost, time to build (labor cost), part count, mistake proofing, manufacturing cost, fixtures quantity and fixture cost, and design efficiency.

Drive improvements through the Competitor Benchmark team. Use ideation process to brainstorm new design ideas, create competitor costed BOM’s (Bill of Material) and estimated assembly time. Identify and drive opportunities to reduce the size of the components.

Measure and track Design for Manufacturing Engineering department performance and continuously improve it.

• Execute department performance scorecard.
• Execute annual department objectives to drive strategic improvements for the department.

Drive testing and troubleshooting of rapid prototypes to characterize the design.

• Generate test plans and procedures to characterize the product.
• Coordinate product testing and report generation.
• Analyze process data.
• Identify opportunities and implement design solutions

Mentor and provide work direction to junior engineers and technicians.

• Meet with junior engineers and technician regularly to provide work direction.
• Meet with the junior engineers periodically to provide guidance on projects and tasks

Manufacturing Engineering functions

• Qualify new and improved processes and technology for manufacturability.
• Support manufacturing with failure analysis and corrective action implementation.
• Perform Assy Method Comparison (Manual, Hard Automation, Flexible-Automation or Robotic Assy).

Continuation Engineering functions

• Review manufacturing processes for inefficiencies
• Identify and implement product improvements where processes could be streamlined.
• Other duties/responsibilities as assigned
  
  

JOB REQUIREMENTS

Education

• Bachelor’s degree in mechanical engineering or equivalent work experience required.
• Six Sigma Greenbelt required.

Experience

• Six to ten years of mechanical or manufacturing engineering in a product development environment required; hearing industry or medical device industry experience preferred.
• Minimum of 3 years’ recent management experience required.

Knowledge / Technical Requirements

• Knowledge of mechanical engineering is required.
• Knowledge of electrical engineering desirable.
• Knowledge of process validation is required.
• Knowledge of new product development systems desired.
• Knowledge of relevant product development methods and best practices (i.e. DFMA, DRM, DFSS, DFT, DOE, DFMEA, Lean PD, Agile development, etc.).

Competencies, Skills & Abilities

• Excellent analytical and problem-solving skills required.
• Excellent people skills required.
• 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
Working Conditions

• Standard office conditions
• Some travel expected to work directly with key customers domestically and internationally.

Equipment Operation

Measure scope/Toolmakers microscope, computer and associated spreadsheet/word processing software, microscope, acoustic test equipment

Salary and Other Compensation:

The target rate for this position is between $93,940 to $110,250 year. Factors which may affect starting pay within this range may include geography/market, skills, education, experience and other qualifications of the successful candidate.

Benefits:
The following benefits for this position, subject to applicable eligibility requirements, include medical, dental, and vision insurance, 401(k) retirement plan with company match, company-paid life insurance, short-term disability insurance, long term disability insurance, employee assistance program, hearing aid benefits, paid time off, paid sick time, and paid holidays.

This position is eligible for a bonus based upon performance results. There is no guarantee of payout.

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