Senior Manufacturing Engineer

Senior Manufacturing Engineer

We are seeking a Senior Manufacturing Engineer to lead the development and optimization of manufacturing processes for new and existing products. This role drives New Product Introduction (NPI), process improvement, automation and quality initiatives to increase throughput, reduce costs, and ensure robust, compliant production. The Senior Manufacturing Engineer works cross-functionally with design, operations, quality, and supply chain to implement scalable, safe, and manufacturable solutions.

Key Responsibilities

• Lead New Product Introduction (NPI) from prototype to production including process design, pilot runs and production transfer.
• Design and optimize manufacturing processes using DFM/DFMA principles to improve yield, reduce cost and shorten cycle times.
• Develop tooling, fixtures, jigs and workholding solutions; oversee fixture design and validation for machining and assembly operations.
• Program and support CNC machining and CAM operations; collaborate on CNC programming and machining strategies for mills, lathes and multi-axis machines.
• Drive process improvement initiatives using Lean, Kaizen, TPM and Six Sigma methodologies to increase capacity and reduce waste.
• Integrate industrial automation and robotics (Fanuc/ABB/KUKA) and implement vision systems, HMI/SCADA and PLC controls to improve consistency and safety.
• Collaborate with cross-functional teams to perform DFMEA/PFMEA, APQP, PPAP and process validation/qualification activities.
• Implement Statistical Process Control (SPC), perform process capability studies (Cp/Cpk) and lead Measurement System Analysis (MSA) and CMM/metrology activities.
• Develop and maintain work instructions, SOPs, BOMs, routings, and ECO/change control documentation.
• Lead root cause analysis and corrective actions (8D, 5 Whys, RCCA) for quality and reliability issues; support failure analysis and test development.
• Partner with supply chain and supplier quality to manage vendor selection, qualification, audits and corrective actions.
• Plan capacity, perform line balancing and production planning; lead cycle time reduction and time-and-motion studies to optimize throughput.
• Champion safety and EHS compliance in manufacturing processes and ensure adherence to ISO 9001, AS9100 and industry-specific regulatory requirements (including FDA/21 CFR where applicable).
• Mentor and coach junior engineers and manufacturing technicians; lead continuous improvement training and project execution.

Qualifications

• Bachelors degree in Mechanical, Manufacturing, Industrial or Electrical Engineering (MS preferred) or equivalent experience.
• 7+ years of manufacturing engineering experience with demonstrated leadership on NPI and continuous improvement projects.
• Proven experience with DFM/DFMA, tooling/fixture design, jigs and fixtures, sheet metal fabrication, injection molding and die casting.
• Hands-on experience with CNC machining, CNC programming, CAM and machining strategies; familiarity with heat treatment and surface finishing processes.
• Experience designing and integrating automation/robotics (Fanuc, ABB, KUKA), vision systems, HMI/SCADA and PLC programming (Allen-Bradley, Siemens).
• Strong background in quality systems and methods: APQP, PPAP, PFMEA/DFMEA, SPC, Cp/Cpk, MSA, CMM/metrology, 8D/5 Whys and RCCA.
• Familiarity with industry standards and regulatory compliance: ISO 9001, AS9100 and FDA/21 CFR where applicable.
• Proficient in CAD (SolidWorks, Creo, AutoCAD) and CAM tools; experience with GD&T, BOM management and work instruction/SOP development.
• Experience with MES, ERP (SAP, Oracle), MRP systems, production planning and capacity planning.
• Skilled in Lean manufacturing tools, Kaizen, TPM, value engineering and cost reduction methods.
• Six Sigma Green Belt required; Black Belt preferred. Experience with Minitab or other statistical software, and familiarity with MATLAB or Python for data analysis.
• Strong project management, cross-functional communication, problem solving, supplier quality/vendor management and change control (ECO) skills.
• Ability to travel to suppliers and other sites as needed; commitment to safety and continuous improvement culture.

Benefits

• Competitive Salary Between $110-125k + 5% Bonus Potential
• Strong Benefits Package (Medical/Dental/Vision, Retirement Savings Options, etc.)
• Unlimited Vacation/Paid Time Off

For this position you must be currently authorized to work in the United States. We do not sponsor for this position.