Process Engineer

Sensata Technologies   •  

Attleboro, MA

Industry: Manufacturing


5 - 7 years

Posted 56 days ago

Sensata Technologies is looking for a Process Engineer who will develop or modify our manufacturing processes to increase product performance, improve manufacturing efficiency and boost profits. This position is located in our Attleboro, Ma headquarters, in close proximity to Boston and Providence. This engineer will work closely with Design Engineers, Equipment vendors, Program Managers, Marketing, and Quality Engineers to support the development of new electromechanical products in primarily the automotive industry. They will be responsible for providing the overall process design and suggesting measures to improve product design for manufacturability. This includes the development of new equipment and process flows as well as developing cost estimates for labor and capital. They will also provide ongoing sustaining support to production lines at our global Make sites.


  • Act as a Process Engineer driving all electro-mechanical issues with responsibility for program success from concept through production release
  • Develop new or improved manufacturing and testing processes that are necessary to achieve the performance and cost requirements of future device applications
  • Facilitate the successful launch of new products
  • Set up sample lines and process development equipment
  • Participate in advanced quality planning activities
  • Specify functional requirements, reviewing designs and debugging/qualifying new high volume assembly/test equipment or tooling
  • Transfer knowledge to make site personnel
  • Support improvement projects to reduce cycle time, defects and manufacturing cost
  • Work with suppliers and contract manufacturers to ensure processes are capable, have sufficient controls in place, can meet our delivery requirements, and meet our cost targets
  • Evaluate Sensata’s and supplier’s technical capabilities including, tooling design, build experience, maintenance program, processes and process controls, cell automation – if required, quality control systems, and materials knowledge
  • Participate in evaluation and selection equipment, and potentially including injection molding machines
  • Influence product designs during new product development phase to ensure economical and defect free manufacture
  • Establish, document, and communicate robust processes and DOE results
  • Develop supporting Process documentation including pFMEA (Design Failure Mode and Effects Analysis), Control Plans, Process Flows
  • Responsible for DFM (Design For Manufacturability) reviews with vendors
  • Demonstrate understanding of basic design principles and performance of classical engineering analysis through calculations, data analysis and data interpretation
  • Present internal and external customer technical presentations to ensure that the product being developed will meet customer expectations
  • Develop project plans
  • Full ownership of process design and development
  • Technology selection, conceptual design, detail design, prototyping
  • Continuous improvement and cost reduction projects
  • Frequent interaction with customers and internal management
  • Collaborate with internal colleagues, and suppliers
  • Meet and exceed customer requirements and expectations on schedule and in budget
  • Learn about in-house and supplier manufacturing technologies
  • Learn about customer systems where our parts are used



  • BS Engineering (Mechanical, Electrical, Industrial, Material Science)
  • 5+ years’ experience in cradle to grave new product development in the industry as a process or design engineer developing advanced Mfg. processes like wire bonding, LASER welding, electrical resistance welding, plastic injection molding, dispensing, thick film printing, SMT, etc..
  • Experience in a Process Engineering role developing robust sensor assembly processes which meet specifications and are economical to manufacture
  • Knowledge of backend electrical function testing and electromechanical device calibration
  • Demonstrated leadership skills and ability to work with little direction
  • Excellent communication skills – written and verbal
  • Strong planning and organization skills
  • Ability to positively influence and build relationships with global team members
  • Engineering aptitude to participate in design reviews and assist during debug & qualification
  • Ability to identify & correct problems by utilization of root cause problem solving skills and experimental methods such as DOE
  • Experience with Agile, Minitab, SolidWorks and background in FEA software a plus
  • Advanced Skills in Microsoft Excel, Project, PowerPoint and Word
  • Functional understanding of advanced quality planning tools including FMEA, Control plans, to meet TS16949 requirements
  • Experience with automotive OEM’s and/or Tier 1 suppliers
  • Willingness to travel internationally to assist the global team and work with our suppliers as needed is a must. Travel can be 3-4 trips per year or more.
  • Preferred, but not required:
  • General knowledge of plastic manufacturing processes, including: injection molding, basic and complex mold design, mold build fabrication, mold operation automation, post-mold automation, and molded part quality inspection
  • Working experience with MEMS products
  • Strong sense of individual responsibility