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Sonova Group · 11 hours ago

Sr. Process Engineer

Aurora, IL

Full-time

Hybrid

Mid, Senior Level

$117K/yr - $170K/yr

4+ years exp

Sonova Group is seeking a skilled Sr. Process Engineer with expertise in process improvement and automation to optimize and automate manufacturing and distribution center processes. The role involves analyzing workflows, designing efficient plant layouts, and implementing automated solutions to enhance efficiency, quality, and safety across North America.

Medical Device

H1B Sponsor Likely

Responsibilities

Identify and analyze process bottlenecks, inefficiencies, and sources of waste using Lean, Six Sigma, or similar methodologies

Drive continuous improvement initiatives to enhance yield, cycle time, and process reliability

Implement data-driven solutions by leveraging process metrics, trend analysis, and root cause analysis (RCA)

Develop and standardize process documentation, procedures, and best practices to ensure scalability and knowledge transfer

Validate processes as required and ensure adherence to medical device regulations and Sonova’s change management process

Foster a culture of engineering excellence and collaboration across manufacturing and engineering teams

Participate in Kaizen events and use SonovaX tools to drive continuous improvement initiatives

Design and implement automated solutions for material handling, sorting, packaging, and storage (e.g., conveyors, robotics, AS/RS systems)

Evaluate and integrate control systems such as PLCs, SCADA, and warehouse management systems (WMS)

Collaborate with vendors and IT teams to ensure seamless integration of automation equipment and software (e.g., SAP)

Define process parameters, build process flow diagrams (PFDs), and establish standard operating procedures (SOPs)

Lead proof-of-concept trials, prototyping, Design of Experiments (DOE), scale-up, and commissioning of new automated systems

Develop and maintain an automation playbook from concept through FAT, SAT, and validation phases

Deploy automated systems developed by global teams across North American sites

Develop and optimize plant and warehouse layouts using AutoCAD or similar tools to improve material flow, space utilization, and efficiency

Conduct time, motion, and space studies to support reconfiguration of work areas and equipment placement

Ensure compliance with safety, ergonomic, and regulatory standards in layout designs

Lead end-to-end execution of engineering projects, including planning, scope, budgets, and timelines

Collaborate with internal teams and external vendors to ensure on-time, within-scope delivery of initiatives

Qualification

Process ImprovementAutomationLean Six SigmaAutoCADSAPRoboticsProject ManagementMinitabSolidWorksCommunication SkillsTeam Player

Required

Bachelor's degree in Mechanical Engineering or Automation

4–6 years of experience in Process Engineering, Automation, Robotics, and Scale-up

Proficient in AutoCAD, SolidWorks, Minitab, and Microsoft Office applications

Strong analytical, organizational, and project management skills

Excellent communication, presentation, and interpersonal abilities

Team player with conflict management and influencing skills

Flexible and willing to travel up to 30%

Identify and analyze process bottlenecks, inefficiencies, and sources of waste using Lean, Six Sigma, or similar methodologies

Drive continuous improvement initiatives to enhance yield, cycle time, and process reliability

Implement data-driven solutions by leveraging process metrics, trend analysis, and root cause analysis (RCA)

Develop and standardize process documentation, procedures, and best practices to ensure scalability and knowledge transfer

Validate processes as required and ensure adherence to medical device regulations and Sonova's change management process