{"id":369031,"url":"https://alion.io/job/bd-staff-engineer-process-development-industrialization","title":"Staff Engineer, Process Development - Industrialization","company":{"id":1821,"name":"BD","domain":"bd.com","url":"https://alion.io/company/bd","size_band":"1001-5000","is_staffing_agency":false,"employer_type":"direct","is_intermediary":false,"listed_via":null,"ats_vendor":"Workday","truth_index":{"grade":"A","score":87,"open_postings":47,"ghost_share":0,"stale_share":0.489,"repost_share":0.064,"time_to_fill_p50_days":32,"computed_at":"2026-11-04T06:34:25Z"}},"role":"Backend","role_family":"Backend","seniority":"staff","employment_type":"full_time","work_mode":"on_site","remote_scope":null,"remote_scope_basis":null,"remote_working_hours":null,"hiring_geo_confidence":"structured","locations":["Covington, United States"],"countries":["US"],"hiring_countries":[],"hiring_countries_total":0,"salary":null,"salary_estimate":{"min_usd":164000,"max_usd":306000,"period":"year","method":"role_seniority_country_remote_cell","sample_n":1500},"experience_years_min":10,"visa_sponsorship":false,"relocation_package":false,"has_equity":false,"technologies":[{"name":"Design Controls","optional":false},{"name":"FMEA","optional":false},{"name":"GMP","optional":false},{"name":"Verification & Validation","optional":false},{"name":"AutoCAD","optional":true},{"name":"GD&T","optional":true},{"name":"SolidWorks","optional":true}],"status":"live","first_seen_at":"2026-06-22T00:00:00Z","employer_posted_date":"2026-06-22","last_verified_at":"2026-11-04T11:13:18Z","board_verified":true,"closed_at":null,"days_open":135,"trust":{"level":"stale","repost_count":0,"flags":["stale"],"days_open":135},"description":"We are the people who give possibilities purpose\nBD 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.\n\nJob Description\nWe 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.\nThe 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.\nKey Responsibilities\nNew Product Development & Industrialization\nLead DFMA strategy for new products and product design changes to ensure successful commercialization and transfer to manufacturing.\nPartner with R&D during product development to influence design decisions that improve manufacturability, assembly, quality, and cost.\nDefine and develop scalable manufacturing processes, equipment concepts, and assembly methods for new product introductions.\nLead engineering efforts to build pilot lines and establish capable, efficient manufacturing processes that achieve performance, quality, and OEE targets.\nSupport internal and external manufacturing transfer activities, including industrialization planning and factory readiness.\nManufacturing Process Development\nDevelop manufacturing processes that meet product requirements, cost targets, and capacity needs.\nPerform DFA, DFMA, DFSS, tolerance stack-up, and risk analyses to optimize designs and reduce manufacturing risk.\nIdentify process improvement opportunities for existing manufacturing operations and implement solutions that improve efficiency, quality, and throughput.\nDevelop and implement risk mitigation plans for assembly processes and ensure process robustness.\nTechnical Leadership\nServe as a subject matter expert in DFMA, assembly engineering, and advanced manufacturing processes.\nProvide technical leadership for cross-functional project teams and lead technical process reviews.\nGuide design teams on best practices for manufacturability, assembly, and process capability.\nPresent technical data, recommendations, and project updates clearly to stakeholders across multiple levels of the organization.\nValidation, Compliance & Documentation\nSupport verification and validation activities for product commercialization, including protocol development, execution, data analysis, and reporting.\nAssist in development of product and process documentation, including design control documentation, process specifications, and inspection/test procedures.\nEnsure all activities comply with applicable quality systems, GMP requirements, and regulatory standards.\nFollow all safety policies, procedures, and site-specific requirements.\nCommercialization Support\nSupport all technical activities related to new product launch, including:Manufacturing process conceptualization and development\nTooling and equipment development\nVendor identification and support\nMake-versus-buy analysis\nSite selection support\nCapital equipment planning\nNew product cost estimates\nMaterial evaluations\nInventory and component planning for development builds\n\nQualifications\nEducation\nBachelor’s degree in Mechanical Engineering, Biomedical Engineering, Chemical Engineering, or a related technical field with 10+ years of relevant experience, or\nMaster’s degree or MBA in Engineering or related field with 8+ years of relevant experience\nRequired Experience\n5+ years of experience in advanced manufacturing engineering, product design, or technical leadership, preferably in medical device or other highly regulated industries\nProven experience applying DFMA principles to product and process development\nExperience leading advanced manufacturing or industrialization initiatives from concept through commercialization\nExperience in process validation, including writing protocols and reports for verification and validation activities\nStrong experience with risk analysis/FMEA, design control, CAD modeling, DFSS, and tolerance stack-up analysis\nExperience with digitalization and automation in manufacturing environments\nPreferred Experience\nMedical device industry experience\nAutomation and semi-automated manufacturing line experience\nExperience with both manual and semi-automated production processes\nTechnical Skills\nWorking knowledge of design and simulation tools such as SolidWorks, AutoCAD, ProModel, and FlexSim\nStrong understanding of GD&T, technical drawings, and part print interpretation\nKnowledge of tooling, drafting, and manufacturing process development\nProficiency in statistical methods for DOE, process characterization, and validation\nAbility to analyze technical data and generate clear, concise reports\nUnderstanding of project planning, budgeting, and capital equipment processes\nCore Competencies\nTechnical leadership and strong engineering judgment\nExcellent project management, planning, and organizational skills\nEffective communication and presentation skills\nStrong collaboration skills across multidisciplinary and global teams\nAbility to work independently and drive projects from concept to implementation\nProblem-solving mindset with strong attention to detail and execution\nTravel\nUp to 25% travel\nWhy Join Us?\nTo 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.\nWe 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.\nTo learn more about BD visit https://bd.com/careers.\nBecton, Dickinson, and Company is an Equal Opportunity Employer. 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