• Staff Engineer, Product & Process Design

    Insight Global (Franklin Lakes, NJ)


    Job Description

    The Staff Engineer is a senior technical leader responsible for integrating product design with advanced manufacturing processes to deliver high‑quality medical devices efficiently. The role focuses heavily on DFMA, automation, assembly process development, and cross‑functional leadership to ensure new products are manufacturable, cost‑effective, and meet quality standards.

    Leading KPI

    1. Product to Market Lead Time

    2. Total Product Assembly Cost

    Lagging KPI

    1. # of Production and Quality issues

    2. OEE by Product Line

    3. Product Gross Margin due to assembly

    Key Responsibilities

    - Lead DFMA, DFSS, and CAD‑based tolerance analyses.

     

    - Develop assembly requirements (KPIVs/KPOVs) and implement process controls.

     

    - Create DFMA review processes and training.

     

    - Conduct risk mitigation and pFMEA for assembly processes.

     

    - Set standards for assembly development within the GIE team.

     

    - Mentor engineers and identify improvement opportunities in existing processes.

     

    - Design new assembly processes meeting OEE, CapEx, and COGS targets.

     

    - Provide IP for assembly solutions and ensure CAD model accuracy.

     

    - Present complex technical data clearly to all organizational levels.

     

    - Support production crises with RCA and problem‑solving tools.

     

    - Ensure compliance with safety and quality regulations.

     

    We are a company committed to creating diverse and inclusive environments where people can bring their full, authentic selves to work every day. We are an equal opportunity/affirmative action employer that believes everyone matters. Qualified candidates will receive consideration for employment regardless of their race, color, ethnicity, religion, sex (including pregnancy), sexual orientation, gender identity and expression, marital status, national origin, ancestry, genetic factors, age, disability, protected veteran status, military or uniformed service member status, or any other status or characteristic protected by applicable laws, regulations, and ordinances. If you need assistance and/or a reasonable accommodation due to a disability during the application or recruiting process, please send a request to [email protected] learn more about how we collect, keep, and process your private information, please review Insight Global's Workforce Privacy Policy: https://insightglobal.com/workforce-privacy-policy/.

     

    Skills and Requirements

     

    10+ years experience as an engineer in the medical device industry

     

    Experience with DFMA (Design For Manufacturing and Assembly), DFSS (Design For Six Sigma)

     

    analysis, and CAD-based Assembly Tolerance Requirement (ATR) analysis

     

    Proven experience leading advanced assembly initiatives

     

    Strong background in CAD, automation, and digital manufacturing tools

     

    Travel up to 25%

     

    Bachelor's in Engineering