Sr. Process Development Engineer

Dexcom • San Diego, CA

1d • $91,400 - $152,300 • Onsite

About The Position

The Sensor Process Development team develops and improves the manufacturing processes and equipment used to produce Dexcom continuous glucose monitoring sensors. We work across the product lifecycle, from early process development and equipment concepting through characterization, validation, technology transfer, and production support. In this role, you will connect process science with practical equipment solutions to improve sensor performance, manufacturing robustness, and scalability across global operations.

Requirements

• Demonstrated hands-on experience developing and improving complex manufacturing processes in a medical device, biosensor, semiconductor, life science, or other regulated environment.
• Understanding of how materials, process parameters, equipment performance, environmental conditions, and test methods interact to influence product performance and manufacturing variability.
• Strong proficiency in statistical analysis, DOE, process capability, Statistical Process Control, test method development, and data-driven problem solving using tools such as JMP or Minitab.
• Experience defining user and process requirements and supporting the design, build, integration, qualification, and deployment of custom manufacturing equipment or automation.
• Skilled in root cause analysis, risk management, process validation, and technical documentation within a quality system.
• Ability to lead complex technical projects, manage competing priorities, communicate recommendations clearly, and drive alignment across R&D, Manufacturing, Quality, Automation, Equipment Engineering, and Operations.
• Comfortable working hands-on in laboratory and manufacturing environments and can move effectively between detailed technical analysis and practical implementation.

Nice To Haves

• Experience with glucose sensors, electrochemical biosensors, coating or dispensing processes, curing, calibration, environmental controls, global technology transfer, or high-volume manufacturing is preferred.

Responsibilities

• Develop, characterize, optimize, and transfer end-to-end glucose sensor manufacturing processes from concept through production implementation.
• Design and execute process characterization studies and Design of Experiments (DOE) to establish critical process parameters, operating windows, and process controls.
• Translate product and process requirements into equipment specifications and partner with equipment, automation, controls, software, and vendors to develop scalable manufacturing solutions.
• Lead technical workstreams for equipment design reviews, testing, qualification, validation, deployment, and manufacturing readiness.
• Analyze development and production data to improve process capability, yield, throughput, equipment reliability, and product quality.
• Lead structured root cause investigations for complex process, equipment, and sensor performance issues and implement sustainable corrective actions.
• Support new product introduction, manufacturing scale-up, and technology transfer between development teams and global manufacturing sites.
• Create clear technical documentation, including requirements, protocols, reports, procedures, risk assessments, and process FMEAs, while providing technical guidance to engineers and cross-functional partners.

Benefits

• A front row seat to life changing CGM technology.
• A full and comprehensive benefits program.
• Growth opportunities on a global scale.
• Access to career development through in-house learning programs and/or qualified tuition reimbursement.
• An exciting and innovative, industry-leading organization committed to our employees, customers, and the communities we serve.

What This Job Offers

• Job Type: Full-time
• Career Level: Senior