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Sensata Technologies, Inc. Process Design Engineer in Attleboro, Massachusetts

Sensata Technologies is looking for a Process Design Engineer who will develop or modify our manufacturing processes to increase product performance, improve manufacturing efficiency and boost profits. This position works closely with Design Engineers, Equipment vendors, Program Managers, Marketing, and Quality Engineers to support the development of new electromechanical products. They are responsible for providing the overall process design and suggesting measures to improve product design for manufacturability. This includes the development of new equipment and process flows as well as developing cost estimates for labor and capital. They will also provide ongoing sustaining support to production lines at our global Make sites.


Job Responsibilities:

  • Influencing product designs during new product development phase to ensure economical and defect free manufacture.

  • Developing new or improve manufacturing and testing processes that are necessary to achieve the performance and cost requirements of future device applications.

  • Facilitating the successful launch of new products.

  • Setting up sample lines and process development equipment.

  • Participating in advanced quality planning activities.

  • Specifying functional requirements, reviewing designs and debugging/qualifying new high volume assembly/test equipment or tooling.

  • Transferring knowledge to make site personnel.

  • Support improvement projects to reduce cycle time, defects and manufacturing cost.

  • Work with suppliers and contract manufacturers to ensure processes are capable, have sufficient controls in place, can meet our delivery requirements, and meet our cost targets.

  • Evaluate Sensata’s and supplier’s technical capabilities including, tooling design, build experience, maintenance program, processes and process controls, cell automation if required, quality control systems, and materials knowledge.

  • Participate in evaluation and selection equipment, and potentially including injection molding machines.

  • Establish, document, and communicate robust processes and DOE results.

  • Document lesson learns for each program.

  • Debug and troubleshoot tooling, equipment and processes using logical engineering principles, including 6 sigma methodology, 5 why analyses, and 8D investigation processes.

  • Lead PE technicians to perform duties in support of process development, equipment debug and troubleshooting, documentation development, Production Trial Runs (PTR’s), Production Validation (PV) builds and Run at Rate builds.

  • Support customer audits of production line equipment, tooling and documentation.

  • Work closely with the product design engineer(s) and quality engineers to provide active feedback on product design, risk and controls throughout the manufacturing process.

  • Assist providing guidelines to ensure Design for Manufacturing/assembly of the new products.

  • Develop process documentation including Working Instructions / FMEA / Control Plan / process flow for the new product and processes.

  • Coordinate and/or perform tooling and equipment concept and design reviews.

  • Determine appropriate machine and process controls for new processes.

  • Write machine specifications and follow up the development of new equipment to ensure that product and process requirements are met by performing a buy-off at supplier’s site.

  • Build Engineering samples, create the Manufacturing Engineering Report for each run and maintain yield tracking sheets for new products.

  • Attend regular team meeting to ensure proper follow up of the program phases.

  • Participate in maturity gates / DE / PE & QA reviews for the programs to ensure the proper follow up of key action that could affect the project execution.

  • Conduct process reviews to keep the program up to date about the process development for the new products.


  • Minimum BS degree in engineering (e.g. Mechanical, Electrical, Industrial, Materials).

  • 5+ years’ experience in “cradle to grave” new product development in the industry as a process or design engineer.

  • Developing advanced Mfg. processes like wire bonding, LASER welding, electrical resistance welding, plastic injection molding, dispensing, thick film printing, SMT etc..

  • Work in a Process Engineering role to develop robust sensor assembly processes which may incorporate complex over-molding, meet specifications, and are economical to manufacture.

  • Knowledge of backend electrical function testing and electromechanical device calibration is desired but not mandatory.

  • Leadership skills and ability to work with little direction.

  • Excellent communication skills written and verbal.

  • Strong planning and organization skills.

  • Ability to positively influence and build relationships with global team members.

  • Engineering aptitude to participate in design reviews and assist during debug & qualification.

  • Ability to identify & correct problems by utilization of root cause problem solving skills and experimental methods such as DOE.

  • Experience with Agile, Minitab, SolidWorks and background in FEA software a plus.

  • Advanced Skills in Microsoft Excel, Project, PowerPoint and Word.

  • Functional understanding of advanced quality planning tools including FMEA, Control plans, to meet TS16949 requirements.

  • Experience with automotive OEM’s and/or Tier 1 suppliers.

  • Willingness to travel internationally to assist the global team and work with our suppliers as needed is a must. Typical travel is 3-4 trips per year.

  • Preferred, but not required:

  • Aptitude in setting up robust injection molding processes on molds including multiple side actions and pin pulls.

  • General knowledge of plastic manufacturing processes, including: injection molding, basic and complex mold design, mold build fabrication, mold operation automation, post-mold automation, and molded part quality inspection.

  • Basic understanding of polymers on a morphological level, and apprehend structure-property relationships.



Smarter Together

  • Collaborating at Sensata means working with some of the world’s most talented people in an enriching environment that is constantly pushing towards the next best thing.

  • Employees work across functions, countries and cultures gaining new perspectives through mutual respect and open communication.

  • As OneSensata, we are working together to make things work together

NOTE: If you are a current Sensata employee (or one of our Affiliates), please back out of this application and log into Workday via the Company Intranet to apply directly. Type "FIND JOBS" in the Workday search bar.

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We are ready for the next century.

Our vision is to be a world leader in mission-critical sensing and electrical protection while satisfying the world’s growing need for safety, efficiency and a clean environment and being a partner, employer and neighbor of choice. Our sensors are the fundamental building blocks needed for a smart, connected, electrified and, ultimately, autonomous world. Click here to find out more about our Future Focus (

Sensing is what we do.

In fact, our name Sensata comes from the Latin word sensate for ‘those gifted with sense’. Our focus on sensing is also reflected in our logo, which spells Sensata in Braille.

Sensata Technologies is a world leader and early innovator in mission-critical sensors and controls designed to make the world cleaner, safer and more efficient. Mission-critical means products that are essential and difficult to do. You’ll find our 47,000 unique products in many applications anywhere from automotive braking systems to aircraft flight controls.

Sensata devices are in systems that protect people and the environment, so what we do matters. We take pride in knowing our technologies improve safety, efficiency and comfort for millions of people every day.

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  • Sensata Technologies, Inc. (US) is proud to be an Equal Opportunity and Affirmative Action employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, gender identity, sexual orientation, age, national origin, protected veteran status, disability or any other basis protected by federal, state or local law.

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