Staff Engineer, Process Development - Industrialization
Confirmed on the employer's own hiring board on Nov 4, 2026. First seen by Alion on Jun 22, 2026. BD scores A on the Alion truth index.
We are the people who give possibilities purpose
BD is one of the largest global medical technology companies in the world. Advancing the world of health™ is our Purpose, and it’s no small feat. It takes the imagination and passion of all of us-from design and engineering to the manufacturing and marketing of our billions of MedTech products per year-to look at the impossible and find transformative solutions that turn dreams into possibilities.
Job Description
We are seeking a highly skilled Product Development Engineer to drive the development of robust manufacturing processes and assembly solutions for new product introductions. This role partners closely with R&D, Operations, and cross-functional engineering teams to ensure products are designed for manufacturability, assembly, quality, scalability, and business success.
The ideal candidate brings deep expertise in Design for Manufacturing and Assembly (DFMA), process development, and technical leadership within a medical device or other highly regulated manufacturing environment. This person will play a key role in launching innovative products by developing efficient, high-quality manufacturing processes and automation strategies that support operational excellence, product quality, and sustainable growth.
Key Responsibilities
New Product Development & Industrialization
- Lead DFMA strategy for new products and product design changes to ensure successful commercialization and transfer to manufacturing.
- Partner with R&D during product development to influence design decisions that improve manufacturability, assembly, quality, and cost.
- Define and develop scalable manufacturing processes, equipment concepts, and assembly methods for new product introductions.
- Lead engineering efforts to build pilot lines and establish capable, efficient manufacturing processes that achieve performance, quality, and OEE targets.
- Support internal and external manufacturing transfer activities, including industrialization planning and factory readiness.
Manufacturing Process Development
- Develop manufacturing processes that meet product requirements, cost targets, and capacity needs.
- Perform DFA, DFMA, DFSS, tolerance stack-up, and risk analyses to optimize designs and reduce manufacturing risk.
- Identify process improvement opportunities for existing manufacturing operations and implement solutions that improve efficiency, quality, and throughput.
- Develop and implement risk mitigation plans for assembly processes and ensure process robustness.
Technical Leadership
- Serve as a subject matter expert in DFMA, assembly engineering, and advanced manufacturing processes.
- Provide technical leadership for cross-functional project teams and lead technical process reviews.
- Guide design teams on best practices for manufacturability, assembly, and process capability.
- Present technical data, recommendations, and project updates clearly to stakeholders across multiple levels of the organization.
Validation, Compliance & Documentation
- Support verification and validation activities for product commercialization, including protocol development, execution, data analysis, and reporting.
- Assist in development of product and process documentation, including design control documentation, process specifications, and inspection/test procedures.
- Ensure all activities comply with applicable quality systems, GMP requirements, and regulatory standards.
- Follow all safety policies, procedures, and site-specific requirements.
Commercialization Support
- Support all technical activities related to new product launch, including:
- Manufacturing process conceptualization and development
- Tooling and equipment development
- Vendor identification and support
- Make-versus-buy analysis
- Site selection support
- Capital equipment planning
- New product cost estimates
- Material evaluations
- Inventory and component planning for development builds
Qualifications
Education
- Bachelor’s degree in Mechanical Engineering, Biomedical Engineering, Chemical Engineering, or a related technical field with 10+ years of relevant experience, or
- Master’s degree or MBA in Engineering or related field with 8+ years of relevant experience
Required Experience
- 5+ years of experience in advanced manufacturing engineering, product design, or technical leadership, preferably in medical device or other highly regulated industries
- Proven experience applying DFMA principles to product and process development
- Experience leading advanced manufacturing or industrialization initiatives from concept through commercialization
- Experience in process validation, including writing protocols and reports for verification and validation activities
- Strong experience with risk analysis/FMEA, design control, CAD modeling, DFSS, and tolerance stack-up analysis
- Experience with digitalization and automation in manufacturing environments
Preferred Experience
- Medical device industry experience
- Automation and semi-automated manufacturing line experience
- Experience with both manual and semi-automated production processes
Technical Skills
- Working knowledge of design and simulation tools such as SolidWorks, AutoCAD, ProModel, and FlexSim
- Strong understanding of GD&T, technical drawings, and part print interpretation
- Knowledge of tooling, drafting, and manufacturing process development
- Proficiency in statistical methods for DOE, process characterization, and validation
- Ability to analyze technical data and generate clear, concise reports
- Understanding of project planning, budgeting, and capital equipment processes
Core Competencies
- Technical leadership and strong engineering judgment
- Excellent project management, planning, and organizational skills
- Effective communication and presentation skills
- Strong collaboration skills across multidisciplinary and global teams
- Ability to work independently and drive projects from concept to implementation
- Problem-solving mindset with strong attention to detail and execution
Travel
- Up to 25% travel
Why Join Us?
To find purpose in the possibilities, we need people who can see the bigger picture, who understand the human story that underpins everything we do. We welcome people with the imagination and drive to help us reinvent the future of healthcare. At BD, you’ll discover a culture in which you can learn, grow and thrive.
We believe that when people connect in person, we learn faster, collaborate more deeply, and build a stronger culture. Join us and enjoy a culture where face-to-face collaboration supports your learning, your progress, and your success.
To learn more about BD visit https://bd.com/careers.
Becton, Dickinson, and Company is an Equal Opportunity Employer. We evaluate applicants without regard to race, color, religion, age, sex, creed, national origin, ancestry, citizenship status, marital or domestic or civil union status, familial status, affectional or sexual orientation, gender identity or expression, genetics, disability, military eligibility or veteran status, and other legally protected characteristics.
Required Skills
Optional Skills
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