Senior Process Engineer

RESPONSIBILITIES:

• The Senior Process Engineer will be responsible for providing drug delivery device production innovation support to project teams developing combination drug delivery devices for parenteral pharmaceutical therapeutics at Genentech.

JOB RESPONSIBILITIES

• The incumbent in this position will be responsible for providing design, development, and commercialization support to project teams that are developing combination drug delivery devices for parenteral pharmaceutical therapeutics at Genentech.
• The candidate will work independently without appreciable direction from project teams or functional management.
• The work is reviewed upon completion.
• This objective will be accomplished by executing activities in the areas of:

PROCESS ENGINEERING

• Provide DFM/DFA assessment of container-device, and development of testing methods to assess container and deliver system quality and functionality for existing and new technologies.
• Use of state-of-the-art technology to lead process development to enable clinical and commercial production in our worldwide network.
• Extensive application of tools to assess design process capabilities such as tolerance analysis, design of experiments, design for reliability, quality by design, design for six sigma, failure modes effect analysis
• Characterize and evaluate critical process parameters (CPPs) using appropriate tools such as DOEs, components of variance, house of quality, etc., leveraging electromechanical presses and custom fixtures to run simulations in the lab.
• Characterize material attributes (MAs) using appropriate tools such as tolerance analyses, empirical / mechanistic modeling with Monte Carlo simulation, etc.
• Support or lead evaluations and investigations applying the most appropriate root cause analysis tools and methodologies.
• Procure lab-scale clinical manufacturing equipment. Design, fabricate, and procure fixtures for device assembly and testing.
• Author / review documentation related to clinical and commercial equipment qualification activities including pFMEAs, FAT, IOQ, and PQ. Author / review process validation protocol(s) and report(s).
• Author / review SOPs for clinical/ commercial manufacturing (including labeling, packaging, preventative maintenance, and equipment operation).
• Provide engineering technical leadership to internal cross functional team and external development partners and component suppliers
• Recommend assembly processes and techniques that provide the most cost effective, robust and reliable performance for medical devices
• Understand, implement, and maintain Roche Pharma Quality Policy and Pharma Quality System (PQS) in the department.
• Developed root cause analysis on manufacturing defects and collaborated in the completion of Engineering
• Change Request (ECR), Material Review Board (MRB), and Corrective and Preventive Action (CAPA)
• Use (and create and implement, if necessary) local PTDU-D procedures and templates ensuring alignment with current versions of PQS documents and best practices.
• Responsible for transfer of design to commercialization
• Ensure product quality and design requirements are traced through the equipment development, process development and validation process.
• Draft, review and/or approve design control documents (i.e. DHF documents) to support device development deliverables using available templates, such as protocols and reports, failure modes effects and analysis, risk management plans, change management plans and design review meeting minutes.
• Employ good document practices (GDP) when recording data, maintaining archives and drafting and reviewing documents.
• Participate in hazards analysis and design assessments and reviews.
• Utilize electronic document archive system and collaborate with Document Control team to ensure document compliance with PQS standards and DHF regulations.
• The candidate has in depth experience in high volume manufacturing processes and methodologies and leads process development to support clinical and commercial production activities within Genentech's device development programs. This includes engaging internal partners and external design/development/manufacturing partners and component suppliers.
• The Senior Process Engineer will be assigned responsibilities to engineering areas and will initiate projects, define critical steps and resources, and develop practical and thorough solutions to complex problems.
• The candidate will work with limited direction and may provide guidance to and coordinate work activities of other personnel.
• The work is reviewed with a focus on long-term perspectives, as the candidate establishes his/her own work priorities and timelines.

Minimum Qualifications:

• Education and Industry Experience - B.S, M.S, or advanced degree in Engineering, with preference for Mechanical Engineering, or the equivalent.
• At least 8 years of experience in the industry and/or academia (including advanced studies) after receiving their Bachelors degree.
• In depth experience in high volume manufacturing processes and methodologies, with an emphasis in plastic molding and mechanical assembly is expected.
• Demonstrated success in project planning, resource management, liaison with engineering and manufacturing resources in other countries is critical.
• Experience working with control systems to be used in production and batch release.
• Strong expertise with statistical handling and interpretation of data, technical report writing and reviewing.
• Familiarity with risk management tools; develop FMEAs of the products and ability to assess changes, non-compliances, etc., with risk assessment methods
• TECHNICAL KNOWLEDGE -Strong skills in relevant modeling and design tools, design controls and/or statistical analysis. Examples may include:
• At least 5 years experience supporting process development from feasibility to New Product Introduction
• Interaction with Equipment/Process: Plastic Heat stake, Plastic Laser welding, Laser Etching, Zebra Printers,
• Leak tests (pressure decay), Flow test, Bubble test, drop test, Pull test, semi-automated and automated
• Assembly equipment, Functional Testers, Smart-scopes, Height gauges, Vision Systems
• Modeling: Monte Carlo Simulations, Tolerance Analysis, Finite Element Analysis.
• Device Design: CADD (Solidworks, AutoCad), Design for Manufacturability, Molding.

Job Type: Contract

Pay: $70.00 - $106.00 per hour

Expected hours: 40 per week

Experience level:

• 8 years
• 9 years

Schedule:

• 8 hour shift
• Day shift
• Monday to Friday

Work setting:

• Hybrid work

Education:

• Bachelor's (Required)

Experience:

• Manufacturing process - Plastic molding: 8 years (Required)
• risk management tools: 8 years (Required)
• CAAD /Solid works: 8 years (Required)
• FMEA of product: 8 years (Preferred)
• Root cause analysis: 8 years (Required)
• Process improvement: 8 years (Required)
• PLASTIC INJECTION MOLDING: 8 years (Required)
• Medical device assembly: 8 years (Required)

Ability to Relocate:

• New Richmond, WI 54017: Relocate before starting work (Required)

Work Location: Hybrid remote in New Richmond, WI 54017