Hybrid Senior Engineer, Process

at Sonova Group

• Job title: Senior Engineer, Process
• Job type: Full Time
• Experience level: Senior
• Salary: $95,200 - $142,800 per year
• Degree requirement: Bachelor's Degree
• Location requirements: Hybrid, Valencia, United States

About the role

• Senior Process Engineer developing welding processes and supporting production for implantable medical devices at Sonova. Collaborates across departments to ensure quality and efficiency in manufacturing processes.

Responsibilities

• Lead welding process development, including microscale hermetic welds, feedthrough integration, and cleanroom-compatible processes.
• Develop and implement process characterization strategies using Design of Experiments (DOE) to optimize parameters and reduce variability.
• Apply statistical analysis tools (e.g., Cp/Cpk, yield, reliability metrics) to evaluate process capability and performance.
• Troubleshoot and resolve complex design, process, and materials issues in Class III implantable medical device manufacturing.
• Support process transfer from development to pilot and full-scale production, ensuring validation and scalability.
• Contribute to capital equipment specification and procurement to support manufacturing process needs.

Requirements

• Bachelor’s degree in Engineering required; Master’s degree preferred.
• Minimum 7–10 years of experience in process engineering, including medical device manufacturing (Class III experience highly desirable).
• Hands-on expertise in welding and automated manufacturing processes (resistance/laser welding, silicone molding, motion control, fluid dispensing, vision inspection).
• Strong background in statistical analysis, Six Sigma, failure analysis, process validation, and process characterization using Design of Experiments (DOE).
• Advanced technical proficiency in process control, mechanical modeling, and engineering drawings (SolidWorks and/or ProEngineer).
• Ability to analyze complex data, drive technical solutions, and collaborate cross-functionally with R&D, Quality, Regulatory, Manufacturing, and Supply Chain.
• Strong communication skills; proficient in English and MS Office/PLM systems (MS Project and statistical software a plus).

Benefits

• Medical, dental and vision coverage*
• Health Savings, Health Reimbursement, Flexible Spending/Dependent Care Accounts
• TeleHealth options
• 401k plan with company match*
• Company paid life/ad&d insurance
• Additional supplemental life/ad&d coverage available
• Company paid Short/Long-Term Disability coverage (STD/LTD)
• STD LTD Buy-ups available
• Accident/Hospital Indemnity coverage
• Legal/ID Theft Assistance
• PTO (or sick and vacation time), floating Diversity Day, & paid holidays*
• Paid parental bonding leave
• Employee Assistance Program (24/7 mental health support hotline, 5 company paid counseling sessions and more)
• Robust Internal Career Growth opportunities
• Tuition reimbursement
• Hearing aid discount for employees and family
• Internal social recognition platform