Role: Senior Sustaining Engineer
Location: Warwick, Rhode Island or Vernon Hills, Illinois
Required Qualifications
Cost Reduction & Value Engineering
Identify and evaluate cost-saving opportunities through design optimization, material substitutions, component standardization, and specification rationalization.
Support development of business cases and prioritize opportunities based on ROI, implementation complexity, risk, and strategic impact.
Drive value engineering initiatives while preserving product functionality, safety, quality, and customer experience.
Partner with Procurement and Supplier Quality to identify supplier-driven cost-saving opportunities.
Design Changes & Sustaining Engineering
Lead design changes associated with Productivity projects, including component, material, supplier, and manufacturing process modifications.
Develop and execute design verification strategies to support product changes.
Generate and maintain required design control documentation, including risk assessments, design outputs, test protocols, reports, and engineering justifications.
Support regulatory submissions and product lifecycle management activities as required.
Technical Analysis & Problem Solving
Conduct engineering analyses to evaluate design alternatives, manufacturing methods, and material options.
Apply structured problem-solving methodologies and data-driven decision-making to identify optimization opportunities.
Perform risk assessments and define mitigation strategies for proposed cost reduction initiatives.
Author technical reports, engineering evaluations, and recommendation documents.
Manufacturing & Operations Collaboration
Partner with Manufacturing, Operations, and Process Engineering teams to improve yield, reduce scrap, simplify assembly processes, and improve overall manufacturing efficiency.
Support equipment upgrades, process improvements, and manufacturing transfers associated with cost reduction initiatives.
Provide technical support during implementation and validation activities.
Supplier Optimization
Support supplier transitions, dual-sourcing initiatives, and material qualifications to reduce cost.
Collaborate with Strategic Sourcing and Supplier Quality teams to evaluate alternate suppliers and technologies.
Lead technical assessments and risk evaluations for supplier-related changes.
Education and Experience:
Bachelor's degree in Mechanical Engineering, Biomedical Engineering, Chemical Engineering, Manufacturing Engineering, or related technical discipline.
Minimum 5 8 years of engineering experience in a regulated manufacturing environment.
Experience in sustaining engineering, product development, operations engineering, manufacturing engineering, or value engineering.
Demonstrated track record of delivering measurable cost savings through engineering solutions.
Experience supporting design controls and engineering change management processes.
Medical device industry experience preferred.
Technical Skills
Value Engineering / Design-to-Cost methodologies
Product cost analysis and cost modeling
Design Controls and Risk Management
Root Cause Analysis and Structured Problem Solving
Statistical Analysis and Experimental Design
Manufacturing Processes and Process Validation
Material Selection and Specification Optimization
Supplier Qualification and Technical Assessment
Leadership Competencies
Strong business acumen and financial mindset
Ability to translate technical solutions into cost savings
Excellent project management and prioritization skills
Effective communication and stakeholder management
Ability to lead cross-functional teams without direct authority
Results-oriented with demonstrated bias for execution
Familiarity with continuous improvement, lean, or design-to-value methodologies used to improve product cost, process efficiency, and portfolio productivity.
Sustaining Engineer • Warwick, RI, United States
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