Staff Engineer, Process Development DFMA & Manufacturing

BD; Covington (VA); On-site; USD 95,000 - 125,000; Full time

Job summary

BD is seeking a Product Development Engineer to drive manufacturing processes for new product introductions, partnering with R&D, Operations, and cross-functional engineering teams to ensure manufacturability, quality, and cost targets.

You will lead DFMA strategies, develop scalable processes, and guide the transfer to manufacturing, with focus on robust, compliant automation in a highly regulated medical device environment.

Qualifications

• 5+ years of experience in advanced manufacturing engineering, product design, or technical leadership.
• 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.

Responsibilities

• 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.
• Develop and implement risk mitigation plans for assembly processes and ensure process robustness.

Skills

DFMA

Advanced manufacturing

Technical leadership

FMEA

CAD modeling

Automation

DOE/Statistics

Project management

Cross-functional collaboration

Education

Bachelor’s degree + 10+ years

Master’s degree or MBA + 8+ years

Tools

SolidWorks

AutoCAD

ProModel

FlexSim

Job description

BD is seeking a Product Development Engineer to drive manufacturing processes for new product introductions, partnering with R&D, Operations, and cross-functional engineering teams to ensure manufacturability, quality, and cost targets.

You will lead DFMA strategies, develop scalable processes, and guide the transfer to manufacturing, with focus on robust, compliant automation in a highly regulated medical device environment.