Location: Aurora, IL, USA (30% travel required across USA, Canada, Mexico, Brazil; occasional global travel)

About the role

We are seeking a skilled Sr. Process Engineer with expertise in process improvement and automation to optimize and automate manufacturing and distribution center processes. This role will analyze workflows, design efficient plant layouts, and implement automated solutions to increase efficiency, quality, and safety. You'll collaborate cross-functionally and lead continuous improvement initiatives across North America.

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.