Design Quality Engineer

Pay 50-60/h depending on experience

“Design Quality Engineer - Process Development to support new product introduction (NPI) and production scale-up activities within the diabetes medical device space. This individual will drive process validation strategies, lead process risk management (PFMEA), and serve as a critical crossfunctional liaison between internal Supplier Quality, R&D, Contract Manufacturers, and NPI teams. The ideal candidate brings deep expertise in process development, FMEA methodologies, and regulatory compliance -A proven track record of resolving critical production issues during scale-up and mentoring engineering teams is essential.

Process Development & Validation

* Develop P-diagrams, Input-Process-Output (IPO) matrices, process characterizations, and test method validation (TMV) strategies for NPI programs.

* Author and manage Master Validation documents (IQ/OQ/PQ/EQV/TMV) for new product introductions and production scale-up.

* Apply methodologies including Design for Reliability and Manufacturability (DRM), Design for Six Sigma (DFSS), Design for Manufacturing Assembly (DFMA),

and Cell Operating System (COS).

* Drive risk mitigation approaches by integrating qualification parts early in process development phases

Process Risk Management & Risk Navigation

* Facilitate and generate Process Failure Modes Effects Analysis (PFMEA) documents for manufacturing processes during NPI and scale-up.

* Maintain strong working knowledge of design risk documentation (RAD, DFMEA, HRA) to critically analyze process-related failures and identify gaps.

* Recognize when process findings have design risk implications and escalate appropriately to Design Quality Assurance (DQA) partners for design risk

assessment decisions.

* Leverage understanding of risk documentation during root cause investigations and critical analyses to ensure comprehensive disposition.

* Conduct thorough root cause investigations using A3 Problem Solving methodology, fishbone diagrams, 5-Why analysis, and brainstorming techniques

Cross-Functional Engagement & Collaboration

* Serve as the primary quality interface between internal Supplier Quality Engineering (SQE), R&D cross-functional teams, Contract Manufacturers, and NPI

program teams

* Facilitate regular cadence of alignment discussions with Supplier Quality and vendors to implement updated control plans, inspection criteria, and risk

documentation.

* Collaborate with R&D teams to translate design intent into manufacturable process parameters during design transfer

* Partner with NPI groups to ensure seamless transition from development builds through production qualification and commercial readiness.

* Ensure alignment between contract manufacturers and internal teams on deliverables, expectations, and quality standards.

* Bridge QMS gaps between contract manufacturing partners and internal quality systems, standardizing documentation templates and expectations.

* Direct comprehensive drawing reviews with cross-functional partners ensuring all Critical Dimensions are accounted for incoming and in-process inspections.

Production Scale-Up Support & Crisis Management

* Lead cross-functional teams through high-pressure production holds and scale-up challenges during NPI commercialization.

* Conduct root cause investigations (A3 methodology) and implement Corrective and Preventive Actions (CAPA).

* Strategize and guide engineering teams to deploy effective investigation approaches for supplier and manufacturing issues.

* Proactively identify production risks during scale-up and drive containment/resolution before they impact launch timelines.

Statistical Analysis & Data-Driven Decision Making

* Perform statistical analyses including hypothesis testing, confidence and tolerance intervals, regression, capability analysis, DOEs, and GR&R using Minitab.

* Utilize statistical process control (SPC), I-MR charts, Box plots, and Normality & No”

Required Skills & Qualifications

* Master’s degree in Mechanical Engineering, Biomedical Engineering, or related field AND 5+ years of experience in process development, manufacturing, or quality engineering for medical devices

OR

* Bachelor’s degree in Mechanical Engineering, Biomedical Engineering, or related engineering field AND 7+ years of experience in process development,

manufacturing, or quality engineering for medical devices”

* 4+ years applying DRM, DFSS, DFMA, and COS methodologies in medical device process development

* 4+ years facilitating and generating PFMEA documents; strong working knowledge of DFMEA and design risk documentation (RAD, HRA) sufficient to identify

gaps and escalate appropriately

* 4+ years developing process parameters, DOEs, P-diagrams/IPO matrices, process characterizations, and process validation strategies (IQ/OQ/PQ/TMV)

* 4+ years performing statistical analysis (hypothesis testing, confidence/tolerance intervals, regression, capability analysis, DOEs, GR&R) in Minitab

* 4+ years working within FDA QSR, ISO 13485, ISO 14971, ISO 11135, ISO 11737, and EU MDR regulatory frameworks

* 4+ years coordinating Design Control, Design Verification, Process Validation, root cause investigations, and CAPA activities

* Demonstrated experience collaborating cross-functionally with Supplier Quality, R&D, Contract Manufacturers, and NPI teams in a matrixed environment

* Demonstrated experience utilizing Good Manufacturing Practices (GMP) and FMECA

Preferred Qualifications

* Experience with CGM (Continuous Glucose Monitoring) sensors or insulin pump systems

* Proven track record resolving production holds during NPI commercialization and scale-up

* Experience managing design transfer and production scale-up activities with contract manufacturers.

* Experience serving as the quality “”bridge”” between multiple external partners and internal stakeholders

* Experience with problem-solving methodology

* CQE (Certified Quality Engineer) or Six Sigma Black Belt certification

* Familiarity with automated manufacturing lines and assembly-level process optimization”