Sr. Mechanical Design Engineer

Job Summary

The Senior Mechanical Design Engineer is a senior technical individual contributor who provides engineering and design leadership in the development of power distribution products for Butcher Power Products. The individual provides technical leadership, optimization, and guidance to the mechanical design team.

This role supports the design and release of high-quality, manufacturable UL 891 products by designing products, conducting technical design reviews, reviewing engineering drawings, identifying continuous improvement opportunities across design, design software, engineering tools, design for manufacturing (DFM) and assembly (DFA), and development processes.

The Senior Mechanical Design Engineer serves as a technical point of contact between Engineering, Manufacturing, and Quality, responding to design-related questions and resolving issues that arise during production.

Key Responsibilities

Technical Leadership

• Serve as a subject matter expert for custom UL 891 low voltage switchboard design, providing technical guidance and mentoring to other design engineers on technical best practices, standards, and process methodologies.

Design Execution

• Complete designs for assigned projects from concept through fabrication-ready documentation, in addition to reviewing the designs of other engineers on the team.

Design Reviews

• Lead and/or participate in design review meetings, reviewing drawings for drafting errors and verifying design intent against fabrication and assembly requirements.

Codes & Standards

• Apply working knowledge of UL 891, UL 50, and UL 50E to switchboard and enclosure design, ensuring designs meet applicable safety, construction, and labeling requirements.

Design for Manufacturability & Assembly

• Provide direct engineering support to production for building issues, design clarifications, and process deviations.

• Participate in root cause analysis and corrective actions related to manufacturing or process issues.

• Apply basic DFM/DFA principles, incorporating practical knowledge of shop floor processes including press brakes, laser cutting, shears, punching, and bending equipment, as well as powder coat/paint or other automated finishing processes, to ensure designs are optimized for fabrication and industrial assembly.

Quality Support

• Support the investigation and root cause analysis process for Non-Conformance Reports (NCRs), and work within the department’s Quality Management System (ISO 9001 or similar regulatory framework).

• Implement continuous improvement to designs, design standards, and projects to reduce waste, improve yield, ensure process compliance, and enhance overall process performance.

Documentation & Standards

• Develop and maintain work instructions, standard operating procedures (SOPs), process control plans, and engineering documentation.

• Review and approve documentation for accuracy, completeness, and compliance with standards.

Data & Documentation Systems

• Maintain accurate design data and documentation within the company’s MRP system (e.g., Microsoft Dynamics D365) and applicable CAD data management tools.

Cross-Functional Collaboration

• Serve as the production engineering point of contact for assigned projects or product lines.

• Coordinate with Manufacturing, Project Management, Supply Chain, Quality, and Engineering departments to align engineering support with operational needs.

Technology

• Review current software and engineering tools to ensure accuracy, efficiency, and ease of use throughout the design process.

Required Qualifications

Education & Experience

• Bachelor’s degree in Mechanical Engineering.

• 7+ years of design, manufacturing, or related engineering experience in a manufacturing or industrial environment.

• Experience with UL 891 and UL 50 product standards.

• Proficiency with SolidWorks.

• Strong knowledge of manufacturing processes, tooling, automation, and production systems.

• Basic knowledge of design for manufacturing (DFM) and design for assembly (DFA) principles.

• Proficient in SolidWorks CAD software, process simulation, and data analysis tools.

• General knowledge of quality systems (ISO 9001, AS9100, etc.), regulatory compliance, and quality processes.

• Strong problem-solving, organizational, project management, and communication skills.

Preferred Qualifications

• Experience working in a manufacturing facility environment, with exposure to press brakes, laser cutting machines, shears, punching machines, bending machines, powder coating/painting processes or other automated painting systems, and industrial assembly applications.

• Six Sigma Green Belt or higher certification, or equivalent continuous improvement credentials.

• Certified SolidWorks Professional (CSWP).

• Experience with PLM/PDM systems and engineering change management workflows (3DEXPERIENCE preferred or SolidWorks PDM).

• Experience with UL 50E, UL 1558, or UL 1640.

• Experience supporting new product introduction (NPI) and production ramp-up activities.

• Experience in regulated or high-reliability manufacturing environments.

• Experience with MRP systems such as Microsoft Dynamics D365.

• Familiarity with electrical switchboard/switchgear manufacturing.

Core Competencies

• Technical Design Leadership & Mentorship

• UL 891, UL 50 & Applicable Industry Standards

• Product Design & Engineering Execution

• Design Reviews & Drawing Quality Control

• Design for Manufacturability (DFM) & Design for Assembly (DFA)

• Root Cause Analysis & Continuous Improvement

• Quality Systems & Regulatory Compliance

• SolidWorks, PDM & Engineering Documentation

• Manufacturing Process Knowledge

• Project & Change Management

• Cross-Functional Collaboration

• Production Engineering Support

Physical Requirements & Work Environment

• Ability to work in both office and manufacturing environments.

• Regular interaction with production equipment, fabrication processes, and assembly operations.

• Ability to walk the manufacturing floor and support production activities as needed.

• Occasional lifting and handling of engineering prototypes, components, and related materials.

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