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Talent Network

Senior Mechanical Engineer (CaSE)

Department: Hardware

Location: Boston

Req#: 3440

We're a global team looking for the best talent - no matter where. This job has the option of working from either our Cambridge, MA or Santa Barbara, CA, office. For the right individual, Sonos will offer relocation reimbursement to either office.

The Sonos Continuing and Sustaining Engineering or CaSE team is tasked with the challenge of maintaining and improving the best audio designs in the industry, Sonos products! We are responsible for all product designs after they are released to production. Challenges include: keeping up with ever-expanding manufacturing volumes, finding and testing ideas for product improvements, efforts to improve yields and drive down costs, improving product reliability, and enhancing manufacturing reproducibility.
About You

Our band is large. And while there’s plenty of room for all kinds of personalities and skill sets to succeed, there are certain qualities that will help you thrive here.

Like a never-accept-less work ethic. An exceptionally low ego-to-talent ratio (none of the first, tons of the latter). A relentless craving to push past your limits and try new things. The smarts and the humble confidence to take on big challenges, make mistakes fast and early, embrace tough feedback, then recover quickly with fresh, startlingly perfect solutions. A fearless willingness to defend great work. And a tendency to totally geek out on music.

If this sounds like you, read on and let’s connect soon.

What You’ll Do
  • Leading Mechanical design projects that drive down costs, improve product yield, improve product reliability, and enhancing manufacturing reproducibility which are invisible to the consumer.
  • Invent tests to break our products! (Sorry, no chicken cannons.) Propose ideas to fix the issue; then develop them into real solutions that make the product more robust. Test and verify the solution, and drive the change implementation into production.
  • Generate and execute validation test plans to qualify new process changes, use of alternative components and suppliers, and/or changes to product design.
  • Prescribe and conduct statistical analyses such as Design of Experiments (DOE) and Statistical Process Control (SPC) to find root cause of in-field and production line failures.
  • Provide technical direction and guidance to Production and Quality Engineers to resolve mechanically-related issues on the production line.
  • Analyze common and/or high-priority field failures. Drive research and testing to find the root cause of failure.
  • Collaborate with Production Engineering, Supplier Quality, and Sourcing teams to identify design weaknesses, opportunities to increase manufacturing yields, and ways to reduce BOM costs.
  • Provide “lessons-learned” feedback to the Product Development team to ensure the next generation of Sonos product is the best it can be.
  • Understand driving factors in customer experience by interfacing with our Quality and Customer Service organizations.
  • Drive continuous improvements in test processes including reliability and repeatability metrics by interfacing with our Manufacturing Test and Manufacturing Quality teams.
  • Interface with multiple partners, both internal and external. e.g. supply chain management, NPI, Product Development, Customer Service, Quality and contract manufacturers.
Skills You’ll Need
  • Proven Mechanical Engineering skills (10+ years), preferably in product development, manufacturing of consumer electronics, and/or production quality control.
  • Manufacturing fabrication processes and tooling for plastic and metal components (injection molding, forming/stamping, casting, extrusions, machining, welding, etc.).
  • Familiarity with dimensional measurement techniques and proficiency with tolerance and stack-up analysis.Depth of experience in the following areas is considered highly desirable:
  • Materials science.
  • Cosmetic and functional finishes.
  • Manufacturing assembly and processing techniques for consumer electronics.
  • Production fixture design.
  • Experience in the Audio, Musical Instrument, or other industries involving high-vibration environments.
  • Experience working with Asian contract manufacturers.
  • Proficiency with 3D parametric CAD and FEA analysis tools (preferably NX and Pro-E).
  • Exceptional trouble-shooting skills are required. Should be able to analyze and trouble-shoot on both paper and via hands-on work.
  • Well-developed reporting and communication skills, including the ability to summarize complicated issues while transcending cultural differences.
  • Candidate should be technically sharp with strong engineering fundamentals. Must understand system level interactions.
  • Must be able to think through a problem on many levels, from production systems to product operation to component specifications.
  • Technically inquisitive – must be able to take on new technical challenges and learn new technical skills on-the-fly, self-researching if necessary. Then must be able to apply the knowledge to solve the issues at hand.
  • Must be able to propose, set up, and execute validation testing plans with minimal guidance for a large variety of design or process changes.
  • Possess a passion for quality and strong attention to detail, particularly for product quality and product verification.
  • Ability to perform validation and reliability tests using a variety of test equipment including environmental test chambers, thermocouples, vibration tables, oscilloscopes, etc.
  • Experience with data collection and familiarity with statistical analysis methods.
How to Audition
Apply now and if there is a strong match, you'll be invited for a first phone interview with one of our recruiters.
More About Our Band

In 2002, we set out to reinvent home audio for the digital age. Our mission–to fill every home with amazing sounding music. Yes, it was an ambitious goal. Challenging, too. And that hasn’t changed.

Since those early days, we’ve remained tirelessly focused on finding innovative ways to make listening out loud, with friends and loved ones, the truly transformative experience it should be. We’ve seen our vision capture the imaginations of music lovers in more than 60 countries, as we’ve continued to introduce products, software, and technologies that help people share the songs they love, discover new music they never knew existed, and experience richer, more musical lives.

At Sonos, we are building a team with extraordinary talent to help us fill every home with music. We are committed to equal employment opportunity regardless of race, color, ancestry, religion, sex, national origin, sexual orientation, age, citizenship, marital status, disability, gender identity or Veteran status.