Staff Manufacturing Process Engineer

About the role

Responsibilities

• Develop, validate, and optimize manufacturing processes from early prototype builds through high-volume production
• Lead manufacturing process validation activities using PFMEA, DOE, capability studies (Cpk), and GR&R
• Drive cross-functional, closed-loop risk mitigation plans by partnering with Design Engineering, Quality, and Operations
• Establish manufacturing readiness plans, process validation strategies, and quality gates for new product introductions
• Partner with Industrial Engineering to evaluate cycle times, line balancing, and resource utilization using Yamazumi charts and time studies
• Drive touch-time reduction initiatives through process optimization, improved assembly sequencing, ergonomic improvements, fastening strategies, automation opportunities and subsystem testing
• Lead structured root cause investigations using 8D, 5 Whys, DOE, and statistical analysis to improve first-pass yield and process capability
• Identify and eliminate manufacturing bottlenecks to improve throughput, labor productivity, and overall equipment effectiveness (OEE)
• Champion Lean Manufacturing, error-proofing (Poka-Yoke), standardization, and continuous improvement initiatives across production
• Own the transition of assembly processes from prototype builds to scalable production systems
• Partner with Quality, Supply Chain, Operations, and NPI teams to successfully launch new manufacturing processes
• Support factory layout development, production line design, capacity planning, and equipment selection
• Support new factory launches, manufacturing transfers, and production ramp activities across domestic and international sites
• 7–10+ years (Senior) or 10–15+ years (Staff) of manufacturing/process engineering experience supporting complex electromechanical products
• Expertise in PFMEA, Control Plans, Process Flow Diagrams, DOE, SPC, 8D, Cpk, and GR&R
• Experience developing scalable manufacturing processes and supporting New Product Introduction (NPI) from prototype through high-volume production
• Experience developing assembly equipment, fixtures, gauges, and automation systems
• Strong knowledge of Lean Manufacturing, Six Sigma, Kaizen, line balancing, Yamazumi charts, time studies, and capacity modeling
• Proven ability to lead cross-functional technical initiatives and influence engineering decisions through data
• Experience working in fast-paced NPI environments with evolving designs and manufacturing challenges
• Experience in automotive, aerospace, energy, or other high-volume electromechanical manufacturing environments