Senior Process Engineer (Onsite)

Our Ambition & Vision

Our ambition is to build a next-generation, best-in-class supply chain that gives ResMed a true competitive advantage through outstanding value, quality, and availability. We strive to be a trusted partner that connects technology, people, and purpose to deliver exceptional outcomes for our customers and patients around the world.

Our vision is to create an intelligent, connected, and reliable supply chain-transparent, data-driven, and always improving. By combining collaboration, innovation, and operational excellence, we're building a network that's agile, sustainable, and ready for the future.

About the Role

As a Senior Process Engineer - Motors Engineering, you'll play a key role in shaping how our products are made. You'll design, refine, and optimize motor manufacturing processes that deliver exceptional safety, quality, and efficiency.

You'll work across engineering, production, and quality teams to ensure smooth transitions from design to high-volume manufacturing-helping ResMed continue to deliver life-changing technology with precision and purpose.

Let's talk about Responsibilities

Process & Equipment Development

• Design, develop, and optimize motor manufacturing processes and tooling to meet quality, performance, and cost targets.

• Lead process validation (IQ, OQ, PQ) to ensure compliance with FDA QSR, ISO 13485, and GMP requirements.

• Apply Design for Manufacture (DFM) and Design for Assembly (DFA) principles to ensure scalable, robust production.

• Develop and enhance automation, test systems, and fixtures using SolidWorks or equivalent tools.

Continuous Improvement

• Analyze production data using Lean, Six Sigma, and DOE techniques to identify improvement opportunities.

• Implement corrective and preventive actions (CAPA) to improve yield, reduce waste, and enhance reliability.

• Drive automation and process optimization to support long-term sustainability and cost efficiency.

Collaboration & Leadership

• Partner with R&D, Quality, NPI, and Maintenance to ensure seamless process transfer and ramp-up.

• Mentor and support junior engineers and technicians, building capability within the team.

• Collaborate with suppliers to develop and qualify robust manufacturing processes and components.

Compliance & Documentation

• Ensure all manufacturing processes meet GMP, EHS, and ISO 13485 standards.

• Maintain accurate, audit-ready process documentation including PFMEAs, control plans, and work instructions.

• Support regulatory audits and internal inspections with confidence and clarity.

Success Metrics

Your success will be measured through your ability to build reliable, compliant, and efficient manufacturing processes that drive measurable impact:

Process Performance

• 98% equipment uptime and process yield for validated production lines.

• Reduction in process deviations and nonconformances by 20% year-over-year.

• On-time completion of process validation and qualification deliverables.

Continuous Improvement

• Minimum two improvement projects per year delivering measurable cost, quality, or efficiency benefits.

• Maintain key process capability (Cpk 1.33) for critical manufacturing parameters.

Safety & Compliance

• Zero recordable safety incidents or audit findings related to manufacturing processes.

• 100% compliance with GMP, ISO 13485, and EHS audit standards.

Collaboration & Growth

• Positive stakeholder feedback across Engineering, Quality, and Operations.

• Demonstrated mentorship and technical leadership within the team.

Let's talk about Qualifications and Experience

• Education: Bachelor's degree in Mechanical, Mechatronics, Manufacturing, or Industrial Engineering.
• Experience: 5-8 years in manufacturing or process engineering, ideally within medical devices or precision manufacturing.
• Skills:
  • Expertise in process validation, DFM/DFA, and continuous improvement.
  • Proficiency in SolidWorks, Minitab, and DOE methodology.
  • Working knowledge of GMP, ISO 13485, and regulatory compliance.
  • Experience in applying functional knowledge and existing methodologies to solve complex problems or execute specialized projects. (moved from preferred)
  • Exercises judgment in selecting methods, techniques and evaluation criteria for obtaining results. (moved from preferred)
  • Strong experience in Design of Experiments (DOE) for process optimization and validation. (edit of original line)
• Preferred
  • Experience with DC motor technologies, including stator and rotor assembly processes, strongly preferred; prior exposure to manufacturing, validating, or optimizing motor sub-assemblies is a plus.
  • Hands-on experience with PLC programming and automation systems for process control (re-worded)
  • Demonstrates aptitude in developing new methodologies and procedures for New Product Introduction (NPI) tasks.
  • Experience with coordinating with and managed external vendors for equipment design/delivery.
• Mindset: Hands-on, data-driven, and collaborative - passionate about building processes that improve lives.

Why Join Us

At ResMed, we believe in "Do it Best, Do it Together."
You'll join a forward-thinking team driving innovation in medical device manufacturing - where engineering precision meets purpose. Together, we're creating smarter, safer, and more sustainable solutions that help people around the world live healthier lives.

We are shaping the future at ResMed, and we recognize the need to build on and broaden our existing skills and continue to attract and retain the world's best talent. We work hard to offer holistic benefits packages, provide flexible work arrangements, cultivate a workforce culture that allows employees to grow personally and professionally, and deliver competitive salaries to our team members. Employees scheduled to work 30 or more hours per week are eligible for benefits. This position qualifies for the following benefits package: comprehensive medical, vision, dental, and life, AD&D, short-term and long-term disability insurance, sleep care management, Health Savings Account (HSA), Flexible Spending Account (FSA), commuter benefits, 401(k), Employee Stock Purchase Plan (ESPP), Employee Assistance Program (EAP), and tuition assistance. Employees accrue fifteen days Paid Time Off (PTO) in their first year of employment, receive 11 paid holidays plus 3 floating days and are eligible for 14 weeks of primary caregiver or two weeks of secondary caregiver leave when welcoming new family members.

Individual pay decisions are based on a variety of factors, such as the candidate's geographic work location, relevant qualifications, work experience, and skills.

At ResMed, it is not typical for an individual to be hired at or near the top of the range for their role and compensation decisions are dependent on the facts and circumstances of each case. A reasonable estimate of the current range for this position is: $117,000 to $175,000

Joining us is more than saying "yes" to making the world a healthier place. It's discovering a career that's challenging, supportive and inspiring. Where a culture driven by excellence helps you not only meet your goals, but also create new ones. We focus on creating a diverse and inclusive culture, encouraging individual expression in the workplace and thrive on the innovative ideas this generates. If this sounds like the workplace for you, apply now! We commit to respond to every applicant.