Sr Mechanical Manufacturing Engineer/Surgical Robotics-OTTAVA

In this role, you will lead manufacturing engineering for the OTTAVA™ surgeon input device, the surgeon-facing control subsystem attached to the Physician Console that captures precise hand inputs used to remotely control surgical instruments and endoscopes. You will integrate mechanical, electrical, firmware, software, assembly, calibration, and test requirements to deliver robust and scalable production processes for this critical electromechanical subsystem.

Purpose

We are seeking a Senior Manufacturing Mechanical Engineer with drive and expertise in precision electromechanical devices and multi-axis controls to lead NPI, assembly, calibration, testing, validation, and industrialization for the OTTAVA™ surgeon input device. This role owns the complete manufacturing engineering lifecycle for surgeon input device assemblies, including precision mechanical subassemblies, multi-degree-of-freedom links and joints, motors, encoders, sensors, cable- and gear-driven elements, and integrated electronics.

Key Responsibilities

• Design and own assembly processes for the OTTAVA™ surgeon input device and its major precision mechanical subassemblies, links and joints, motors, encoders, sensors, and integrated electronics.
• Develop assembly sequence logic that controls system error, friction, preload, transmission tension or engagement, encoder alignment, and cumulative variation across the device workspace.
• Define and validate datum schemes, fixturing strategies, and measurement methods that maintain consistent reference frames from component-level assembly through full device integration.
• Author and release manufacturing processes for complex electromechanical assemblies, including MPIs, travelers, eDHR workflows, process maps, and inspection criteria.
• Define assembly and inspection processes for integrated electromechanical assemblies incorporating bearings, shafts, belts, cables, springs, seals, shims, adhesives, lubricants, fasteners, PCAs, harnesses, and precision-machined structures.
• Determine component-, subassembly-, and device-level metrology, instrumentation, and test requirements for assembly reliability and verification.
• Define and implement precision assembly equipment and fixtures designed for scalable industrialization, such as fastening systems, micro-torque tools, press-fit equipment, bonding and dispensing systems, and alignment fixtures.
• Develop and improve the mechanical processes and inputs that influence calibration and test outcomes, including assembly setup, alignment, preload, friction, and other mechanical parameters used in system calibration, performance testing, burn-in, and functional verification.
• Use SPC, capability analysis, yield data, and issue Pareto analysis to detect drift, prioritize root-cause investigations, and improve first-pass yield and cycle time.
• Develop and mature manufacturing processes from prototype and pilot builds through validated, repeatable, and scalable production.
• Develop project plans and execute process development, equipment, documentation, and validation deliverables through implementation.
• Troubleshoot mechanical, electromechanical, sensing, calibration, and test failures in partnership with R&D, Test Engineering, Quality, Operations, and suppliers.
• Lead manufacturing change control, configuration updates, and production release activities in partnership with Engineering, Quality, and Operations.
• Monitor, coach, and mentor junior engineers and technicians on precision assembly, calibration, validation, and manufacturing best practices.

Cross-Functional Collaboration & Technical Leadership

• Establish strong working relationships with R&D, Development Engineering, Operations Process Engineering, Quality Assurance, and Production to design, develop, test, document, and implement processes, tooling, and fixtures.
• Partner with Quality to proactively address and resolve nonconformances before they affect production.
• Identify process requirements, advise operations management, and implement equipment and fixtures for process development and manufacturing.
• Lead cross-functional technical reviews, communicate risks and tradeoffs, and drive timely decisions from development through production implementation.
• Provide technical coaching and feedback to engineers and technicians on process development, problem solving, validation, and manufacturing best practices.
• Maintain attention to detail while moving with urgency and ensuring critical actions are completed.

Qualifications

Education: Bachelor’s degree in Mechanical Engineering, Mechatronics, Biomedical Engineering, Robotics, Precision Engineering, or related field.

Required Experience: 8-10 years of manufacturing or assembly engineering experience, with a minimum of 5 years supporting precision electromechanical mechanisms, haptic devices, robotic controls, medical capital equipment, or comparable high-reliability systems.

• Demonstrated expertise in precision mechanism assembly, including bearing preload, cable-, belt-, or gear-driven mechanisms, encoder and sensor integration, motor assemblies, alignment, bonding, and controlled lubrication.
• Strong manufacturing engineering background — BOM structure, process documentation (MPI, DHR, MES), and PFMEA.
• Medical device experience with a proven track record in NPI environments.
• Electromechanical Systems: Extensive troubleshooting capability across mechanical, electrical, and instrumentation domains.
• CAD Proficiency: Expert-level skills in CAD design (SolidWorks preferred), ASME Y14.5 GD&T, and 3D tolerance stack-up analysis.
• Strong statistical proficiency — SPC, Cpk, DOE, Minitab, or equivalent.
• Demonstrated experience developing and implementing end-to-end manufacturing processes for precision electromechanical assemblies, including process flows, tooling, fixtures, measurement strategies, assembly equipment, documentation, and process controls.
• Proven experience maturing manufacturing processes from prototype or pilot builds through validation, launch, and scalable production.
• Experience planning and executing cross-functional process development, equipment, documentation, and validation deliverables.
• Quality Systems: Over 3 years in J&J (or equivalent regulated environment), fully trained and proficient in J&J systems, SOPs, and processes.

Skills

• Systems-level thinking that connects component and assembly precision to full-device system accuracy, friction, calibration performance, input fidelity, reliability, and surgeon experience.
• Exceptional technical writing capability for regulatory-grade process documentation.
• Strong leadership presence with the ability to drive alignment across R&D, Quality, Regulatory, and Operations without direct authority.
• Passion for precision and defect prevention in a life-critical product environment.
• Deep curiosity about mechanism design and a hands-on instinct for understanding how products are built and how they fail.
• Ability to translate technical requirements into clear manufacturing plans, align cross-functional stakeholders, and communicate risks, decisions, and implementation status.
• Commitment to building processes that are capable today and robust and scalable as production volumes grow.

Preferred

• Master’s degree in Mechanical Engineering, Mechatronics, Biomedical Engineering, Robotics, or Precision Engineering.
• Direct experience with surgical robotics, haptic interfaces, force-feedback devices, teleoperation controls, or surgeon-facing input mechanisms.
• Certification: Six Sigma Black Belt.
• Experience with precision calibration and test systems for multi-axis electromechanical assemblies.
• Experience with system calibration, encoder calibration, friction characterization, parameter testing, and burn-in of robotic or haptic mechanisms.
• Familiarity with industrial communication protocols, real-time motion control, motor drives, and sensor communication architectures.
• Experience with micro-assembly, magnification-assisted assembly, precision bonding and dispensing, bearing installation, and cable, belt, or gear-drive setup.
• Experience applying SPC, capability analysis, DOE, and structured root-cause analysis to improve yield, friction performance, calibration results, and cycle time.
• Experience with MES systems and PLM tools in regulated industries.

Other

Cultural Fit – Non-Negotiable Attributes: Sense of Urgency, Proactive Ownership, Transparent Communication, Attention to Detail, High Drive.

Working Style: Proven ability to work in a collaborative, cross-functional environment while maintaining individual accountability. Strong project management skills with ability to manage multiple parallel NPI programs. Excellent troubleshooting mindset — persistent in finding root causes. Comfortable challenging design decisions when manufacturing concerns arise. Thrives in ambiguity and rapidly changing priorities.

Attendance: Fully Onsite. This role will require commuting to our Milpitas Site, 25% Travel requirements: 10%.