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BD (Becton, Dickinson and Company) Sr. Staff Engineer - Molding & Tools Operations in Franklin Lakes, New Jersey

Job Description SummaryWith limited direction from the Associate Director – Molding & Tools Operations leads new product development, capacity expansion and the development of molding technologies for Diabetes Care products with specific focus on high cavitation tool designs, problem solving and refinement of current technologies to optimize performance of current production platforms. This individual will train and develop junior team members through new product introductions with concept development, prototyping and launch/commercialization tooling and production strategy including in-house vs. contract manufacturing. This individual would support manufacturing plants in cost reduction, standardization and equipment upgrade projects, use of scientific problem solving techniques combined with scientific injection molding process development. Works closely with R&D and manufacturing plants to implement manufacturing technologies. Has reasonable understanding of plastic product assembly designs and techniques. Can assume the role of Core Team Member on New Product Development Core Teams representing Operations function.

Job Description

Molding & Tools Operations / Manufacturing Process Technology
  • Leads development and design of high volume production tools and processes (primarily injection molding), including pilot production, process feasibility, optimization and validation. Knowledge of various assembly techniques and types of platforms and packaging is plus.

  • Leads design, built and validate high cavitation tools using different types of hot runner systems, gating technology for plastic parts with very tight tolerances.

  • Leads the efforts on developing new solutions in high cavitation tool and hot runner design for small and intricate plastic components with high capability requirements.

  • Leads the purchase of production equipment. Develops the specifications and acceptance protocols.

  • Leads the management of vendors in the design, development and implementation of manufacturing equipment.

  • Leads the application of six-sigma and lean manufacturing methodologies in projects to optimize manufacturing equipment.

  • Develops molding processes by following scientific injection molding principles, designing and/or performing DOEs, data analysis, preparation of reports, and providing recommendations.

  • Leads project’s manufacturing & tooling strategy from technical as well as business needs stand point.

  • Applies BD-standardized manufacturing technologies, practices and protocols.

  • Supports the manufacturing plants in cost reduction, standardization and equipment upgrade projects.

  • Provides input into department strategy.

Leadership, Guidance & Development
  • Exhibits strong interest and desire of self-development and growth.

  • Has capability and desire to have junior members of team as direct reports, work with them on daily basis, develop/train them and be responsible for their performance and deliverable.

Knowledge & Problem Solving
  • Applies extensive and in-depth technical expertise in a manufacturing process technology and has extensive knowledge of other related process technologies. Develops technical solutions to complex problems which require the regular use of ingenuity and creativity.

  • Guides the successful completion of major manufacturing initiatives and may function in a project leadership role. Erroneous decisions or recommendations would typically result in failure to achieve major objectives.

Discretion / Latitude
  • Work is performed without appreciable direction. Exercises considerable latitude in resolving technical and business objectives of assignment.
Liaison
  • Represents the organization as the prime technical contact on contracts and projects. Interacts with senior external personnel on significant technical matters often requiring coordination between organizations.
Project Management
  • Leads complex projects to design, prototype, build and commercialize manufacturing process equipment. Initiate, plan, execute, monitor, control, and close these projects.
Cross Functional Collaboration
  • Works with product design and development teams to ensure robust manufacturability of new products and to estimate capital and product costs.

  • Works with diverse functions and manufacturing sites. Collaborates with teams of engineers and technicians and coordinate assets to achieve goals.

Core Team Member
  • Represents Operations function at Core Team on NPD projects.

  • Works with Molding SMEs and Assembly/Automation SMEs to devise Manufacturing Strategy (In-house, External/CMO) for new products considering various aspects of COGS, Capital, TCO, Technical Complexity, Technical Capabilities, critical initiatives and use of new/innovative manufacturing techniques.

  • Prepares COGS (Cost of Goods Sold) and Capital requirement from Launch to 10 Year marketing forecast considering in-house/external manufacturing options.

  • Prepares, maintains and provides updates on Operations integrated project plan for all phases of new product development in compliance with GPDS or any other phase gate process.

  • Manage capital budgets and provides status reports to management in a timely basis.

  • Actively prepares and handles all risks associated with design and manufacturing. Educates and updates top management on risk management tasks & activities.

  • Being responsible for timely execution and completion of all manufacturing related tasks for new product launch, including build and validation of internal and external tools and platforms.

  • Follows division policies and guidelines.

  • Other duties as assigned.

Experience & education:

Required: minimum B.S. Plastics/Mechanical or other relevant engineering field plus ten years proven experience in all areas of Plastics Engineering with focus on medical device design, high cavitation tool design, molding process development using scientific injection molding principles, molding technology sensing, evaluation and implementation, project management and the design / implementation of manufacturing equipment / processes.

Experience in the area of Medical sterile disposable devices is preferable.

Experience in working with equipment suppliers and all levels of manufacturing plant personnel.

Knowledge, skills and abilities:
  • Must understand the overall project and business requirements and recommend manufacturing strategy to support successful product launches with potential annual sales in the range of $40 - $400 million.

  • Strategic grasp of manufacturing standard methodologies, state of the art and latest manufacturing technology in the plastic molding area.

  • Experience in sensing, developing and implementation of new technologies in plastics injection molding tools, processes & platforms, hot runner designs and product handling.

  • Ability to work and influence decision-makers across multiple sites.

  • Knowledge of the interrelationship of Manufacturing Operations and Finance, Quality, Regulatory and Supply Chain in an FDA/ISO regulated environment. Experience in collaborating with these functions to achieve objectives.

  • Experience in preparing equipment specifications, capital appropriations and process validation documentation.

Enhanced skills & abilities:

  • Executes responsibilities with a large degree of autonomy requiring minimal day-to-day oversight by immediate supervisor.

  • Interpersonal savvy to engage and gain the support of associates in various positions of responsibility and in various functions within BD worldwide. This includes associates in these functions who occupy positions of authority that is equal to, greater than or less than the incumbent. Ability to communicate effectively the value proposition of new technologies, designs, project plans and resource requirements.

  • Enhanced complexity with the ability to deal with a wide variety of processes such as molding (micro molding), assembly (electro-mechanical, plastic components etc.), inspection methods, packaging and sterilization of which any combination must meet the integrated requirements of medical use, chemical / biological compatibility, manufacturability, and acceptable cost.

  • Enhanced influence and authority representing BD when collaborating with external vendors / suppliers, as designs and processes are developed/finalized and capital equipment is purchased.

Becton, Dickinson and Company is an Equal Opportunity/Affirmative Action Employer. We do not unlawfully discriminate on the basis of race, color, religion, age, sex, creed, national origin, ancestry, citizenship status, marital or domestic or civil union status, familial status, affectional or sexual orientation, gender identity or expression, genetics, disability, military eligibility or veteran status.

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Primary Work LocationUSA NJ - Franklin Lakes

Additional Locations

Work ShiftNA (United States of America)

Becton, Dickinson and Company is an Equal Opportunity/Affirmative Action Employer. We do not unlawfully discriminate on the basis of race, color, religion, age, sex, creed, national origin, ancestry, citizenship status, marital or domestic or civil union status, familial status, affectional or sexual orientation, gender identity or expression, genetics, disability, military eligibility or veteran status, or any other protected status.

Becton, Dickinson and Company is an Equal Opportunity/Affirmative Action Employer. We do not unlawfully discriminate on the basis of race, color, religion, age, sex, creed, national origin, ancestry, citizenship status, marital or domestic or civil union status, familial status, affectional or sexual orientation, gender identity or expression, genetics, disability, military eligibility or veteran status, or any other protected status.

All applicants should complete the on-line application process. BD is committed to working with and providing reasonable accommodations to individuals with disabilities. If you require assistance or an accommodation because of a disability to participate in the application process, please call 855-BD-HELPS (855-234-3577) or email asc.americas@bd.com

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