Senior Manufacturing Engineer

Job Summary:

We are seeking a highly skilled and experienced Manufacturing Operations Engineer with a strong focus on New Product and Part Development. This role is responsible for driving manufacturability, cost-efficiency, and scalability of new products from concept through production launch. The ideal candidate will have extensive experience working with cross-functional teams to translate design intent into robust manufacturing processes, ensuring smooth integration of new parts into production with a strong focus on quality, timing, and cost.

Key Responsibilities:

New Product Introduction (NPI) & Part Development:

• Collaborate with R&D, Product Design, and Supply Chain teams to ensure Design for Manufacturability (DFM) and Design for Assembly (DFA) principles are embedded early in the product lifecycle.
• Lead manufacturing readiness reviews and process capability studies during the development of new parts and products.
• Develop, validate, and optimize manufacturing processes, tooling, and fixtures for new components and assemblies.
• Own process development plans, including process flow diagrams, PFMEAs, control plans, and work instructions.
• Interface with suppliers to support the development, qualification, and industrialization of externally manufactured components.

Launch & Scale-Up:

• Support pilot builds, prototypes, and low-rate initial production (LRIP) to validate manufacturing feasibility and ensure process stability.
• Coordinate with production teams to ensure a smooth transition of new parts/products into full-scale manufacturing.
• Monitor process KPIs during ramp-up and initiate continuous improvement actions where necessary.

Cross-functional Collaboration & Technical Leadership:

• Act as the technical liaison between engineering, quality, supply chain, and operations for all NPI and part development activities.
• Participate in design reviews, change management (ECO/ECR), and stage-gate or APQP processes.
• Mentor junior engineers and support knowledge transfer across engineering and production teams.

Quality, Compliance & Documentation:

• Ensure new parts and processes meet all quality, safety, and regulatory requirements (e.g., ISO 9001, IATF 16949, AS9100, FDA as applicable).
• Create and maintain all necessary documentation including process validation reports, first article inspection (FAI), and PPAP/FAIR packages.
• Support root cause analysis and corrective actions for development-related quality issues.

Required Qualifications:

• Education:
• Bachelor's degree in Mechanical, Manufacturing, Industrial, or related Engineering field. Master's degree is a plus.
• Experience:
• 5–15 years of experience in a manufacturing engineering role with a strong focus on new product development, part industrialization, and process development.
• Technical Skills:
• Strong knowledge of DFM/DFA, process validation, GD&T, and statistical analysis tools.
• Proficient in CAD software (e.g., SolidWorks, CATIA, Creo) and engineering documentation platforms (e.g., PLM systems).
• Experience with manufacturing methods such as machining, injection molding, die casting, stamping, additive manufacturing, etc.
• Familiarity with quality tools such as FMEA, Control Plans, PPAP, FAIR, SPC, and root cause analysis techniques (8D, 5-Why, Ishikawa).
• Knowledge of ERP/MES systems and production documentation standards.

Preferred Qualifications & Certifications:

• Lean Six Sigma Green/Black Belt
• PMP or experience with structured project management
• Experience working in APQP or stage-gate product development environments
• Exposure to Industry 4.0 and smart manufacturing tools