Process Engineer

Who we are

In a life without sound, our work provides meaning. As a leading provider of innovative hearing care solutions, we are not just a company that makes products: we are a team on a mission to help people enjoy the delight of hearing. To enable a life without limitations, through our core business brands – Advanced Bionics, Audiological Care, Phonak, Sennheiser (under license) and Unitron – we develop, manufacture and distribute solutions that push the limits of technology and redefine the future of our industry.

Aurora, IL- USA

Process Engineer  

This position will support Engineering projects to Launch New Products, Develop and improve manufacturing processes for both New and Service. This role requires thorough knowledge of manufacturing processes, electronic devices and engineering in a highly regulated Medical Device company.  The Process Engineer will be responsible for execution of engineering projects tied to process improvement, process development, NPI - New Product Introduction to Manufacturing sites, automation, Robotics, validation, monitoring and reporting and other initiative as directed by the Sr. Manager, Process Engineering while following the quality and regulatory processes for medical devices. This role will also own the Quality inspection process for one of our products from process improvements to decision making.

This position will be based in Aurora, IL-USA, but it will require 25% travel to other sites within the region – USA, Canada, Mexico, and Brazil—and may involve one-off travel to other sites globally.

Responsibilities:

• Closely work with HQ, ME-Manufacturing Engineering Team, and site engineering teams for development and implementation of New or enhanced processes
• Implement New Processes for service through optimization, improvement, root cause analysis.
• Conduct bench testing on all products, hearing instrument components and processes within the AODC engineering lab
• Be a Subject Matter expert on end-to-end manufacturing processes such as 3D printing, assembly, Surface coating & curing, Electroacoustic Testing etc.
• Validate processes as needed per the QMS & SOP
• Create a work instruction, Prepare Layout
• Leads Service Layout Changes by working with site Engineers and Streamlining the process

• Reviews and supports Validation of Service processes and changes in the region

Process Ownership:

• Own assigned product/process lines from process setup, scale up, sustainment and decision making
• Responsible for review and release of couple of products daily for quality inspections i.e. one of Sonova product Lyric.
• Be the subject matter expert on assigned processes to resolve any process or material issues tied to the product
• Sign off on release of products to the next process step through thorough investigation, and analysis
• Provide guidance to the QA team on do’s and don’ts on inspection processes

Process Improvement:

• Maintain internal data collection, perform data analysis, interpret findings and disseminate reports
• Use the SonovaX tools to help drive Continuous Improvement within manufacturing processes
• Be part of Kaizens as Engineering representative to help improving operation KPI
• Recommend Optimal Layouts to improve the manufacturing processes of medical device.

Process Development:

• Evaluate, prototype and develop manufacturing technologies and processes to automate Key process steps in the manufacturing process
• Develop New process to optimally manufacture electronic hearing aid devices
• Leverage already existing manufacturing processes from HQ and optimize the manufacturing processes through process development, automation and technology integration.

Project Management:

• Manage Key projects from inception through validation and roll out

Other:

• SAP Knowledge to improve processes.
• Collaborate with operations, training department to provide technical direction and on-the-job training to technicians.
• Analyze reports, look back data, and other data to plan and design work.
• Work cohesively with operations teams, operation training team, global Research and Development teams, Quality teams, and Sustaining Engineering teams

General knowledge of other Production Support related discipline

More about you:

Education & Experience:

• Bachelor’s degree in electrical/Electronic or Mechanical Engineering
• Material science knowledge
• 3-4 years’ experience in Process Engineering
• Automation and Robotics Experience

Skills & Competencies:

• Proficient in English
• Manufacturing Processes
• Computer experience, working knowledge of Microsoft products including Office, SAP Experience (or other ERP system) a plus
• AutoCAD, Solidworks knowledge is a plus, but not required
• Strong analytical and organizational skill
• Team player and go getter

Personal Attributes:

• Strong interpersonal, communication and presentation skills.
• Able to interact with corporate development teams and present new concepts
• Able to conduct hands on experience with product and processes.
• Ability to handle multiple projects simultaneously

A minimum of 200Mb/sec download and 10Mb/sec upload speed internet connectivity is required to support any remote/hybrid employee functionality at Sonova

Don't meet all the criteria?  If you’re willing to go all in and learn we'd love to hear from you! 

We are looking forward to receiving your application via our online job application platform. For this position only direct applications will be considered. Sonova does not recruit via app, telegram, carrier pigeon or any other format that does not include speaking with an actual human. If you are offered a job without speaking with someone please contact  

 What we offer:

• Medical, dental and vision coverage*
• Health Savings, Health Reimbursement, Flexible Spending/Dependent Care Accounts
• TeleHealth options
• 401k plan with company match*
• Company paid life/ad&d insurance
  • Additional supplemental life/ad&d coverage available
• Company paid Short/Long-Term Disability coverage (STD/LTD)
  • STD LTD Buy-ups available
• Accident/Hospital Indemnity coverage
• Legal/ID Theft Assistance
• PTO (or sick and vacation time), floating Diversity Day, & paid holidays*
• Paid parental bonding leave
• Employee Assistance Program (24/7 mental health support hotline, 5 company paid counseling sessions and more)
• Robust Internal Career Growth opportunities
• Tuition reimbursement
• Hearing aid discount for employees and family
• Internal social recognition platform
• D&I focused: D&I council and employee resource groups

*Plan rules/offerings dependent upon group Company/location.

This role's pay range is between: $71,000 – 102,600.00  . This role is also commission eligible/bonus eligible. 

How we work:

At Sonova, we prioritize the well-being of our employees and foster an inclusive environment that promotes engagement and collaboration. Our team-customized hybrid work model empowers teams to balance individual needs with business goals, offering flexibility and individualized time management. We recognize the importance of life outside of work and strive to create a supportive and motivating workplace where innovation thrives