Sustaining Manufacturing Design Engineer (China travel)

Orion Sleep; San Francisco (CA); Hybrid; USD 90,000 - 130,000; Full time

Job summary

Orion Sleep is seeking a Manufacturing Design Engineer to own sustaining quality and process health for Gen 1 products. The role spans SF office and manufacturing partners in China, serving as the single point of accountability for changes across FATP and Tier 2 supply chains.

You will design plastic and metal components, drive vendor improvements, and run DOEs while using data to justify actions. Travel to China ~30–40% is required; strong CAD (Onshape) skills and English fluency are essential.

Qualifications

• 3+ years of mechanical engineering experience with manufacturing or sustaining role
• Strong mechanical design skills across injection molded plastics, sheet metal, and production tooling including test fixtures, jigs, and functional testers
• Demonstrated ability to use data to drive decisions: yield trends, SPC, field return analysis, or similar
• Hands-on experience working with FATP and Tier 2 contract manufacturers, ideally in Asia
• Comfortable building quick experiments: setting up test rigs, instrumenting assemblies, running DOEs, interpreting results
• Strong failure analysis instincts - form hypotheses, design tests, and reach defensible conclusions
• Experienced in ECO and change management processes
• Willingness to travel to China regularly (estimated 30-40%)
• Proficient in CAD (Onshape)
• Fluent in English; Mandarin fluency is a significant advantage

Responsibilities

• Own the full sustaining change lifecycle: problem identification → failure analysis → corrective action → design → validation → production implementation
• Design mechanical components as needed - injection molded plastics, sheet metal, and similar - to resolve field failures or address process gaps
• Drive process improvements at FATP and Tier 2 vendors, including designing, reviewing, and implementing testers, fixtures, and jigs for IQC, IPQC, and OQC stations
• Use production yield data, field return rates, and process metrics to build data-driven justifications for specific design and process changes - you quantify problems before proposing solutions
• Set up and run workbench experiments and DOEs to evaluate corrective actions, including thermal, mechanical, and process-level characterizations
• Work directly and on-site with manufacturing vendors in China to root cause failures, improve process consistency, and qualify changes
• Own part lifecycle and change management: define rollout timelines, coordinate across supply chain, and ensure changes land cleanly in production
• Analyze customer returns and field data to drive prioritization

Skills

Mechanical design

Data-driven decisions

DOE/testing

Manufacturing liaison

Failure analysis

Change management

Manufacturing partnerships

Travel readiness

CAD on Onshape

English fluency

Tools

Onshape CAD

Job description

Orion Sleep is seeking a Manufacturing Design Engineer to own sustaining quality and process health for Gen 1 products. The role spans SF office and manufacturing partners in China, serving as the single point of accountability for changes across FATP and Tier 2 supply chains.

You will design plastic and metal components, drive vendor improvements, and run DOEs while using data to justify actions. Travel to China ~30–40% is required; strong CAD (Onshape) skills and English fluency are essential.