Senior Manufacturing Engineer

American BOA is a leading manufacturer of flexible metal components and systems, serving industries such as automotive and aerospace. With a legacy of innovation and precision engineering, we are committed to delivering high-performance solutions that meet the most demanding technical requirements.
We foster a collaborative and quality-driven culture where engineers are empowered to innovate, solve complex problems, and contribute to the future of advanced manufacturing.

Position Summary

We are seeking a highly skilled and experienced Senior Manufacturing Engineer to lead process development, optimization, and simulation initiatives. This role will be instrumental in driving manufacturing excellence and supporting new product introductions. The ideal candidate will also have hands-on experience with DEFORM software for metal forming simulation and a strong understanding of manufacturing best practices, manufacturing equipment and control systems.

Key Responsibilities

• Lead manufacturing process design, improvement, and validation for new and existing products.
• Utilize DEFORM software to simulate and optimize metal forming processes, primarily via hydroforming.
• Collaborate with design, tooling, and production teams to implement simulation-driven improvements or root cause analysis.
• Develop and maintain process documentation including flow charts, work instructions, and control plans.
• Conduct root cause analysis and implement corrective actions for process-related issues.
• Support APQP, PPAP, and other quality assurance processes.
• Drive lean manufacturing initiatives and continuous improvement projects.
• Mentor junior engineers and support cross-functional project teams.
• Analyze manufacturing data using statistical tools and perform Measurement Systems Analysis (MSA).
• Work with hydraulic systems, control systems, and measurement equipment to support production and troubleshooting.

Qualifications

• Bachelor’s degree from an ABET accredited institution in Mechanical Engineering (Master’s preferred).
• Minimum 7 years of experience in a manufacturing engineering role.
• Proficiency in DEFORM software for process simulation and analysis.
• Strong knowledge of metal forming, material science, and structural behavior.
• Experience with CAD tools (SolidWorks, AutoCAD, PTC Creo).
• Familiarity with ERP systems and manufacturing analytics.
• Expertise in lean manufacturing, Six Sigma, and process optimization.
• Experience with hydraulic systems and general knowledge of manufacturing equipment control systems.
• Proficiency in using measurement equipment.
• Strong background in statistical analysis and Measurement Systems Analysis (MSA).
• Excellent communication, leadership, and project management skills.

Preferred Skills

• Experience in automotive or aerospace manufacturing environments.
• Knowledge of APQP, PPAP, FMEA, and SPC.
• Ability to interpret metallurgical data and integrate it into simulation models.
• Hands-on experience with prototyping and testing.