Senior Sustaining Engineer

Senior Sustaining EngineerLocation: Warwick, Rhode Island or Vernon Hills, IllinoisRequired QualificationsCost Reduction & Value EngineeringIdentify 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 EngineeringLead 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 SolvingConduct 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 CollaborationPartner 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 OptimizationSupport 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 SkillsValue Engineering / Design-to-Cost methodologiesProduct cost analysis and cost modelingDesign Controls and Risk ManagementRoot Cause Analysis and Structured Problem SolvingStatistical Analysis and Experimental DesignManufacturing Processes and Process ValidationMaterial Selection and Specification OptimizationSupplier Qualification and Technical AssessmentLeadership CompetenciesStrong business acumen and financial mindsetAbility to translate technical solutions into cost savingsExcellent project management and prioritization skillsEffective communication and stakeholder managementAbility to lead cross-functional teams without direct authorityResults-oriented with demonstrated bias for executionFamiliarity with continuous improvement, lean, or design-to-value methodologies used to improve product cost, process efficiency, and portfolio productivity.