Senior Manufacturing Engineer

Senior Manufacturing EngineerMicroAire Surgical Instruments, (Charlottesville, VA) is a wholly-owned subsidiary and one of five companies within the Medical Group of Marmon Holdings, a Berkshire Hathaway company. MicroAire is a mid-sized medical device solutions company with a 45-year legacy of quality and innovation. With well-recognized brands, the company is uniquely positioned as a leader in specialty markets, including minimally invasive medical devices and equipment for aesthetics/reconstruction, endoscopic soft tissue release, and orthopedic accessories. MicroAire designs, manufactures, and markets cutting-edge medical devices that empower surgeons to push the boundaries of surgical precision, delivering safe, efficient, and high-quality patient outcomes.Position SummaryThe Senior Manufacturing Engineer provides technical leadership for manufacturing operations supporting both existing products and new product introductions, with a strong emphasis on plastic injection molding processes, tooling, automation, and process optimization.This role is responsible for developing, validating, optimizing, and sustaining molding processes and manufacturing systems that improve product quality, scalability, and operational performance. You'll collaborate cross-functionally, solve complex challenges, and help shape future manufacturing capabilities through innovation, scientific molding, and continuous improvement.What You'll DoLead Design for Manufacturing (DFM) and Design for Assembly (DFA) efforts focused on injection molded components, improving manufacturability, quality, and costDevelop, validate, and optimize injection molding processes, tooling, fixtures, automation systems, and secondary operationsEstablish and refine molding parameters (fill, pack, hold, cooling, resin drying, cycle time) using scientific molding principlesSupport mold design reviews, tooling qualification, first article inspection, and production readinessTroubleshoot molding defects such as flash, sink, short shots, warp, splay, burns, and dimensional variationPartner with tooling vendors, resin suppliers, and automation integrators to improve mold performance and uptimeEvaluate and implement advanced manufacturing technologies including robotics, vision systems, and smart manufacturing solutionsLead new product introduction (NPI), process validation (IQ/OQ/PQ), DOE studies, and production launch readinessDevelop scalable manufacturing strategies that support growth, efficiency, and long-term performanceAuthor and maintain key documentation including PFMEA, control plans, work instructions, and process flowsLead engineering changes including tolerance analysis, resin evaluation, and mold/process improvementsServe as technical lead for complex manufacturing and quality challenges, driving root cause analysis and corrective actionsDrive continuous improvement using Lean, Six Sigma, Kaizen, and scientific molding methodologiesMentor Manufacturing Engineers and Process Technicians, supporting technical growth and capability developmentPartner cross-functionally with Engineering, Operations, Quality, Supply Chain, and external stakeholders to achieve business objectivesWhat You BringRequired:Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, Plastics Engineering, or related field5+ years of manufacturing engineering experience, ideally supporting injection molding or high-volume production environmentsHands-on experience with injection molding process development, scientific molding, tooling validation, and troubleshootingPreferred:Experience with automation, robotics, vision systems, or advanced manufacturing technologiesKnowledge of engineered thermoplastics, resin behavior, and mold flow principlesTechnical Expertise:Deep understanding of injection molding processes, tooling design, and process optimizationStrong troubleshooting capability across molding defects, cycle optimization, and process stabilityExperience with validation (IQ/OQ/PQ), DOE, SPC, and statistical analysisKnowledge of GD&T, tolerance analysis, and plastic part design considerationsFamiliarity with Lean manufacturing and continuous improvement methodologiesProfessional Strengths:Strong analytical and data-driven problem-solving skillsAbility to lead complex projects and influence cross-functional teamsExcellent documentation and process standardization practicesEffective communicator with the ability to work across all levels of the organizationPassion for innovation, continuous improvement, and technical excellenceReady to Make an Impact?If you're a subject matter expert in plastic injection molding who thrives on solving complex challenges and driving manufacturing innovation, this is your opportunity to lead and shape the future of high-performance manufacturing.Join a collaborative team where your expertise will directly influence product quality, operational excellence, and next-generation manufacturing capabilities.Our Benefits:Competitive Salary: $100,000 – $120,000401(k) Retirement Plan with Company MatchComprehensive Medical, Dental, and Vision InsurancePaid Time Off and Company HolidaysAccess to Career Development and Networking Opportunities Across Marmon Holdings