Senior Manufacturing Process Engineer

At Sonos we want to create the ultimate listening experience for our customers and know that it starts by listening to each other. As part of the Sonos team, you’ll collaborate with people of all styles, skill sets, and backgrounds to realize our vision while fostering a community where everyone feels included and empowered to do the best work of their lives.

Join the revolution that is delivering the best audio experience in the world as a member of the team responsible for the delivery of product assembly for Sonos’ next-generation speakers. In this role, you are the owner of critical assembly processes for new product development projects—including mechanical assembly, system assembly, and packaging. You will lead engineers from contract manufacturers to develop fixtures, equipment, automated assembly machines, and associated standard operating procedures (SOPs). You will own the resolution of manufacturing process-related issues, support failure analysis of design issues from a manufacturing process engineering perspective, and ensure products transition smoothly into high-volume production with exceptional build quality and reliability.

What You’ll Do

● Own assigned assembly processes across mechanical assembly, system assembly, and packaging for new product development and mass production (MP).

● Clarify product requirements with Product Design (PD) and Manufacturing Design Engineering (MDE), conduct robust manufacturability analyses (DFM/DFx), provide alternative mechanical design proposals, and control technical risks throughout the Product Creation process.

● Lead in the development of new manufacturing processes, partnering with Contract Manufacturers (CM) and Sonos supplier teams to ensure processes are well-documented, statistically capable, and well-controlled.

● Define manufacturing fixture, tooling, and equipment specifications to meet line balance, cycle time, and capacity requirements (UPH) for all prototype builds and mass production.

● Lead engineers from contract manufacturers and automation vendors to design, develop, and qualify fixtures, custom assembly equipment, automated machinery, and comprehensive SOPs.

● Lead prototype builds and mass production ramps on-site from the Manufacturing Process Engineering perspective to proactively detect build issues and formulate immediate containment and short-term solutions with PD.

● Capture all build issues during build events, lead rigorous root-cause analysis (for both process and component failures) using 8D, DOE, and PFMEA methodologies, and drive corrective actions to full closure.

● Establish, evaluate, and monitor process capability metrics (Cpk, GR&R) while driving continuous improvements in yield, cycle time, line balancing, and Manufacturing Value Add (MVA) cost reduction.

● Continually track, evaluate, and benchmark emerging manufacturing technologies, advanced joining techniques, and automation solutions to leverage them for Sonos products.

What You’ll Need

Basic Qualifications

● Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Mechatronics, Automation, or equivalent.

● 8+ years of hands-on experience in mechanical manufacturing engineering or mechanical design development within the consumer electronics or precision hardware industry.

● Proven track record realizing consumer electronics products in mass production involving precision mechanical parts assembly and strict cosmetic requirements.

● Deep technical expertise across mechanical parts assembly and joining technologies, including several of the following: adhesives (RTV, AB, CA, PSA etc. ), gaskets, electro-mechanical part DIP & soldering, heat staking, ultrasonic welding (USW), precision screwing, laser etching, and packaging assembly.

● Solid knowledge and extensive hands-on experience in Design for Manufacturability (DFM/DFx), with the ability to understand, challenge, and resolve tolerance stack-up analyses to meet tight gap and step specifications.

● Demonstrated experience using advanced analysis and problem-solving techniques, including Design of Experiments (DOE), failure analysis, 8D problem solving, Cpk, GR&R, and PFMEA.

● Extensive experience in production line development methodologies, including flow charts, cycle time calculation, UPH setup, line layout & balancing, SOP authoring, and MVA calculation.

● Proficiency in 3D CAD mechanical design software (e.g., Creo/Pro-E, NX/UG, or Catia).

● Fluent in written and spoken English and Mandarin, with the ability to communicate effectively across global engineering teams and manufacturing partners.

● Qualified applicants must be able to work from the office 5 days per week in Shanghai and be willing to travel extensively within China and internationally to the US.

Preferred Qualifications

● Demonstrated leadership experience (e.g., Project Lead, Technical Lead, or Team Lead) guiding CM engineering teams during NPI ramp-up.

● Experience developing unique or customized manufacturing processes, specialized assembly automation lines, and intelligent tooling.

● Background in acoustic product manufacturing, with hands-on familiarity in system air-leak detection and acoustic Rub & Buzz failure analysis.

● Familiarity with digital factory and shop-floor execution systems (MES/ERP).

● A genuine passion for music and audio technology!

Your profile will be reviewed and you'll hear from us once we have an update. At Sonos we take the time to hire right and appreciate your patience.