Senior Development Engineer

Summary
The Senior Development Engineer is responsible for designing and developing new processes to support new product development and enable smooth transfer of processes into manufacturing. The role focuses on delivering robust technical solutions, ensuring high-quality outcomes, and contributing to overall organizational growth through successful process development.

Responsibilities

New Process and Product Development (Primary Function)

• Develop manufacturing processes for new or evolving product designs.
• Provide design-for-manufacturability guidance, including material selection, process selection, and feature optimization.
• Lead development of tooling, equipment specifications, process documentation, and related engineering drawings.
• Build, test, and refine development processes, ensuring they meet quality, reliability, and cost expectations prior to launch.
• Execute validation activities such as IQ, OQ, and PQ in alignment with industry standards.
• Collaborate with customers, suppliers, testing partners, and cross-functional teams to support development activities.
• Apply Lean and Six Sigma tools to process design, including minimizing changeover time, improving process capability, implementing error-proofing, and optimizing workflow.
• Use a scientific, data-driven approach to evaluate process inputs, run limits testing, and assess process capability.
• Support early-stage customer engagement by helping communicate the value and purpose of development activities.
• Conduct safety and risk assessments for new equipment and processes.
• Perform additional related engineering duties as required.

Support of Existing Business (Secondary Function)

• Address advanced technical issues related to existing production processes.
• Support cost‑reduction, quality improvement, and operational efficiency initiatives across teams.
• Contribute to ongoing improvements in performance, delivery, and safety.

Accountabilities

• Support revenue growth objectives related to successful development and commercialization of new processes.
• Contribute to cross-functional project goals, including quality and cost improvement targets.
• Support technical execution that aligns with organizational objectives for innovation and process robustness.
• Help ensure new tooling and process launches meet success and reliability targets.

Qualifications

Education and Experience

• Engineering degree or equivalent technical background.
• Deep expertise in rotary converting processes, including web handling, die cutting, laser or mechanical cutting, registration systems, sensing, and vision inspection.
• Ability to visualize and conceptualize rotary converting workflows based on customer parts or drawings.
• Approximately 10-15 years of relevant engineering experience.
• Working knowledge of Lean and Six Sigma methodologies.
• Experience with regulated environments such as GMP or ISO 13485.
• Background in process validation (IQ/OQ/PQ), preferably for regulated or medical products.
• Experience with packaging systems or automated vision systems is beneficial.
• CAD experience in designing tools, components, and engineering drawings.

Competencies and Attributes

• Strong team‑oriented attitude with humility, motivation, and high situational awareness.
• Expert-level understanding of rotary converting principles, process behavior, and tooling requirements.
• Excellent communication skills for both internal and customer-facing interactions.
• Strong organizational skills with the ability to manage multiple concurrent projects.
• Proficiency in reading and interpreting engineering drawings and GD&T.
• Ability to challenge assumptions using data, hands-on experimentation, and creative problem‑solving.
• Strong decision‑making skills, especially in fast-paced or high‑pressure situations.