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Senior Process Engineer/Product Care Leader

South San Francisco, California


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The Position

The incumbent in this position will be responsible for providing design, development, and commercialization support to project teams that are developing combination drug delivery devices for parenteral pharmaceutical therapeutics at Genentech.  The candidate will work independently without appreciable direction from project teams or functional management.  The work is reviewed upon completion.This objective will be accomplished by executing activities in the areas of:

Process Engineering:

  • Provide DFM/DFA assessment of container-device, and development of testing methods to assess container and deliver system quality and functionality for existing and new technologies.

  • Use of state-of-the-art technology to lead process development to enable clinical and commercial production in our worldwide network.

  • Extensive application of tools to assess design process capabilities such as tolerance analysis, design of experiments, design for reliability, quality by design, design for six sigma, failure modes effect analysis

  • Characterize and evaluate critical process parameters (CPPs) using appropriate tools such as DOEs, components of variance, house of quality, etc., leveraging electromechanical presses and custom fixtures to run simulations in the lab.

  • Characterize material attributes (MAs) using appropriate tools such as tolerance analyses, empirical / mechanistic modeling with Monte Carlo simulation, etc.

  • Support or lead evaluations and investigations applying the most appropriate root cause analysis tools and methodologies. 

  • Procure lab-scale clinical manufacturing equipment.  Design, fabricate, and procure fixtures for device assembly and testing.

  • Author / review documentation related to clinical and commercial equipment qualification activities including pFMEAs, FAT, IOQ, and PQ.  Author / review process validation protocol(s) and report(s).

  • Author / review SOPs for clinical/ commercial manufacturing (including labeling, packaging, preventative maintenance, and equipment operation).

  • Provide engineering technical leadership to internal cross functional team and external development partners and component suppliers

  • Recommend assembly processes and techniques that provide the most cost effective, robust and reliable performance for medical devices

Product Care:

  • Coordinate and manage all aspects of commercial change management for combination products and medical devices

  • Create change impact assessments and implementation plans in collaboration with SMEs from Device Development including resource planning

  • Manage change execution per defined implementation plan

  • Accountable for maintenance and update of device risk assessments and DHF documents

  • Support, coordinate and drive resolution of unexpected product and manufacturing events

  • Support commercial complaint investigations

  • Manage a product care team responsible for planning and execution as needed

Quality Systems Compliance:

  • Understand, implement, and maintain Roche Pharma Quality Policy and Pharma Quality System (PQS) in the department.

  • Developed root cause analysis on manufacturing defects and collaborated in the completion of Engineering

  • Change Request (ECR), Material Review Board (MRB), and Corrective and Preventive Action (CAPA)

  • Use (and create and implement, if necessary) local PTDU-D procedures and templates ensuring alignment with current versions of PQS documents and best practices.

  • Assist with resolving issues arising from internal quality assessments/audits, regulatory inspections and notified body interactions, and aid in driving closure of inspection issues by preparing appropriate responses and corrective action resolutions.

  • Create and review discrepancy, change and risk management documents for PTDU-D and Devices Teams, as appropriate.

  • Ensure compliance of training to PQS and job-related requirements.

Design Control:

  • Responsible for transfer of design to commercialization

  • Ensure product quality and design requirements are traced through the equipment development, process development and validation process. 

  • Draft, review and/or approve design control documents (i.e. DHF documents) to support device development deliverables using available templates, such as protocols and reports, failure modes effects and analysis, risk management plans, change management plans and design review meeting minutes.

  • Employ good document practices (GDP) when recording data, maintaining archives and drafting and reviewing documents.

  • Participate in hazards analysis and design assessments and reviews. 

  • Utilize electronic document archive system and collaborate with Document Control team to ensure document compliance with PQS standards and DHF regulations.

Interfaces and Collaboration:

  • Regularly interface with leaders in Contract Manufacturing, Procurement, Quality, Complaints and Regulatory Affairs.

  • Regularly interact at a detailed technical level with design engineers, equipment and production engineers.

  • Support supplier selection through assessment of supplier capabilities for existing equipment and custom automation development, acceptance and installation

  • Collaborate with internal / external teams to translate design requirements into clinical and commercial processes

QUALIFICATIONS

Education and Industry Experience

  • B.S, M.S, or advanced degree in Engineering, with preference for Mechanical Engineering, or the equivalent.

  • At least 8 years of experience in the industry and/or academia (including advanced studies) after receiving their Bachelors degree.

  • In depth experience in high volume manufacturing processes and methodologies, with an emphasis in plastic molding and mechanical assembly is expected.

  • Demonstrated success in project planning, resource management, liaison with engineering and manufacturing resources in other countries is critical.

  • Experience working with control systems to be used in production and batch release.  

  • Strong expertise with statistical handling and interpretation of data, technical report writing and reviewing.  

  • Familiarity with risk management tools; develop FMEAs of the products and ability to assess changes, non-compliances, etc., with risk assessment methods.

Technical Knowledge:

Strong skills in relevant modeling and design tools, design controls and/or statistical analysis. Examples may include:

  • At least 5 years experience supporting process development from feasibility to New Product Introduction

  • Interaction with Equipment/Process: Plastic Heat stake, Plastic Laser welding, Laser Etching, Zebra Printers,

  • Leak tests (pressure decay), Flow test, Bubble test, drop test, Pull test, semi-automated and automated

  • assembly equipment, Functional Testers, Smart-scopes, Height gauges, Vision Systems

  • Modeling: Monte Carlo Simulations, Tolerance Analysis, Finite Element Analysis.

  • Device Design: CADD (Solidworks, AutoCad), Design for Manufacturability, Molding.

  • Full data and statistical analysis (JMP, Minitab) and Design of Experiments, and providing detailed review of data with an emphasis on statistics.

  • Design Controls for regulatory compliance & filing (ISO 13485, etc): GDP/GLP/GMP, Design History Files, User Requirement Specifications (URS), Factory/Site Acceptance Testing (FAT/SAT), test protocols, technical reports, control systems to be used in production and batch release and risk management tools (methods, FMEAs, non-compliances, etc)..

  • Six Sigma (Green/Black Belt): DMAIC and DFSS

Interpersonal Skills:

  • Proven track record of working effectively in a matrix organization with a highly cross-functional (e.g., validation, quality, and program management) and collaborative environment is very desirable.

  • Excellent oral and written communication skills are required.  

  • Able to work with external design/development and production partners is also highly desirable.

  • Highly organized and detail oriented.

  • Excellent leadership skills.

  • Demonstrated success in project planning, resource management, and liaising with engineering and manufacturing resources in other countries.

TRAINING REQUIREMENTS:

Core training is mandatory and must be completed within the allotted time frame beginning with on-board date.  Initial training requirements are listed in this section.

Additional training to enhance Core requirements may be assigned as elective courses.  These elective courses are deemed essential to performing the job duties related to this position.

This role may be based out of our South San Francisco headquarters OR remotely, anywhere in the United States with the exception of Colorado. Colorado applicants are not eligible. Relocation assistance for Colorado residents is available for this role.

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Who We Are

Genentech, a member of the Roche group and founder of the biotechnology industry, is dedicated to pursuing groundbreaking science to discover and develop medicines for people with serious and life-threatening diseases. To solve the world's most complex health challenges, we ask bigger questions that challenge our industry and the boundaries of science to transform society. Our transformational discoveries include the first targeted antibody for cancer and the first medicine for primary progressive multiple sclerosis.

Diversity and Inclusion (D&I) are critical to the success of our company and our impact on society. We believe that by championing diversity of background, thought and experience, we can foster a sense of belonging and provide an environment where every employee feels valued, included, and able to contribute their best for the patients we serve. We’re focused on attracting, retaining, developing and advancing our people to their full potential by rewarding bold ways of thinking and integrating inclusive behaviors into every aspect of our work.

The next step is yours. To apply today, click on the "Apply for this job" button.

Genentech is an equal opportunity employer & prohibits unlawful discrimination based on race, color, religion, gender, sexual orientation, gender identity/expression, national origin/ancestry, age, disability, marital & veteran status. For more information about equal employment opportunity, visit our Genentech Careers page.


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