Sr. Process Engineer

Sonova USA, Inc. • Aurora • $117k - $170k / year • 1w ago

Who we are

At Sonova, we envision a world where everyone can enjoy the delight of hearing. This vision inspires us and fuels our commitment to developing innovative solutions that improve hearing health and human connection - from personal audio devices and wireless communication systems to hearing aids and cochlear implants. We're dedicated to providing outstanding customer experiences through our global audiological care services, ensuring that everyone has the opportunity to engage fully with the world around them.

Guided by a culture of continuous improvement that fosters resilience and self-motivation, our team is united by a shared commitment to excellence and a deep sense of pride in our work, each of us playing a vital role in creating meaningful change,

Here you'll find a diverse range of opportunities that span both consumer and medical solutions and the freedom to shape your career while making an impact on the lives of others. Join us in our mission to create a more connected world, where every voice is heard and every story matters.

Aurora (IL), United States

Sr. Process Engineer

Aurora, IL

Sr. Process Engineer

About the role

We are seeking a Sr. Process Engineer with strong experience leading automation initiatives in manufacturing and distribution environments. This role is responsible for identifying automation opportunities, developing ROI cases, partnering with vendors, and taking solutions from concept through installation, validation, and production ramp-up. You will work cross-functionally to improve efficiency, quality, safety, and scalability across North American operations.

Responsibilities

Process Engineering
- Identify and analyze process bottlenecks, inefficiencies, and sources of waste using Lean, Six Sigma, or similar methodologies.
- Drive continuous improvement initiatives to enhance yield, cycle time, and process reliability.
- Implement data-driven solutions by leveraging process metrics, trend analysis, and root cause analysis (RCA).
- Develop and standardize process documentation, procedures, and best practices to ensure scalability and knowledge transfer.
- Validate processes as required and ensure adherence to medical device regulations and Sonova's change management process.
- Foster a culture of engineering excellence and collaboration across manufacturing and engineering teams.
- Participate in Kaizen events and use SonovaX tools to drive continuous improvement initiatives.
Process Development & Automation
- Design and implement automated solutions for material handling, sorting, packaging, and storage (e.g., conveyors, robotics, AS/RS systems).
- Evaluate and integrate control systems such as PLCs, SCADA, and warehouse management systems (WMS).
- Collaborate with vendors and IT teams to ensure seamless integration of automation equipment and software (e.g., SAP).
- Define process parameters, build process flow diagrams (PFDs), and establish standard operating procedures (SOPs).
- Lead proof-of-concept trials, prototyping, Design of Experiments (DOE), scale-up, and commissioning of new automated systems.
- Develop and maintain an automation playbook from concept through FAT, SAT, and validation phases.
- Deploy automated systems developed by global teams across North American sites.
Plant Layout & Project Management
- Develop and optimize plant and warehouse layouts using AutoCAD or similar tools to improve material flow, space utilization, and efficiency.
- Conduct time, motion, and space studies to support reconfiguration of work areas and equipment placement.
- Ensure compliance with safety, ergonomic, and regulatory standards in layout designs.
- Lead end-to-end execution of engineering projects, including planning, scope, budgets, and timelines.
- Collaborate with internal teams and external vendors to ensure on-time, within-scope delivery of initiatives.

More about you

Bachelor's degree in Mechanical Engineering or Automation (Master's preferred)
4-6 years of experience in Process Engineering, Automation, Robotics, and Scale-up
Experience in manufacturing or warehouse environments preferred
Proficient in AutoCAD, SolidWorks, Minitab, and Microsoft Office applications
Familiarity with SAP or other ERP systems
Strong analytical, organizational, and project management skills
Excellent communication, presentation, and interpersonal abilities
Team player with conflict management and influencing skills
Flexible and willing to travel up to 30%

What we offer

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
Short/Long-Term Disability coverage (STD/LTD)
Accident/Hospital Indemnity coverage
Legal/ID Theft Assistance
PTO, floating Diversity Day, & paid holidays*
Paid parental bonding leave
Employee Assistance Program (24/7 mental health support, 5 paid counseling sessions)
Internal career growth opportunities
Tuition reimbursement
Hearing aid discount for employees and family
Internal social recognition platform

*Plan rules/offerings dependent upon group Company/location.

This role's pay range is between: $117,000 - $170,000. This role is also bonus eligible.

How we work

At Sonova, we prioritize the well-being of our employees and foster an inclusive environment that promotes engagement and collaboration. Our team-customized hybrid work model empowers teams to balance individual needs with business goals, offering flexibility and individualized time management. We recognize the importance of life outside of work and strive to create a supportive and motivating workplace where innovation thrives.

Ready to join us?

Don't meet all the criteria? If you're willing to go all in and learn, we'd love to hear from you!

We look forward to receiving your application via our online job application platform. For this position, only direct applications will be considered. Sonova does not recruit via app, telegram, carrier pigeon or any other format that does not include speaking with an actual human. If you are offered a job without speaking with someone, please contact Sonova Human Resources.

Sonova is an equal opportunity employer.

We team up. We grow talent. We collaborate with people of diverse backgrounds to win with the best team in the market place. We guarantee every person equal treatment in regard to employment and opportunity for employment, regardless of a candidate's ethnic or national origin, religion, sexual orientation or marital status, gender, genetic identity, age, disability or any other legally protected status.

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