Senior Manufacturing Engineer

Role: Manufacturing Engineer | Greenfield Mfg. Launch / Process Readiness
Location: Pittsburgh, PA
Role Overview:
The Manufacturing Engineer will be responsible for developing, validating, and launching manufacturing processes for a large-scale greenfield manufacturing facility .
This role supports the end-to-end industrialization journey from early process planning through equipment installation, commissioning, production ramp-up, and operational handovers.
The role focuses on translating products, process, quality, safety, capacity, and business requirements into capable, repeatable, scalable, and efficient manufacturing systems. The ideal candidate will combine strong manufacturing engineering fundamentals, hands-on shop-floor experience, and cross-functional leadership to support large-scale factory launch and ramp-up.
Key Responsibilities:
Lead manufacturing process development from concept planning through production launch and ramp-up.
Define production line requirements, workstation concepts, tooling and fixture needs, equipment interfaces, labor assumptions, process flows, and manufacturing documentation.
Develop and maintain work instructions, SOPs, process flow diagrams, routings, standardized work, cycle time studies, production checks, and launch readiness checklists.
Partner with Product Engineering, Operations, Quality, Equipment Engineering, Controls Engineering, Industrial Engineering, Layout Engineering, Supply Chain, Facilities, Construction, EHS, and Maintenance teams to integrate manufacturing requirements into the overall plant design.
Provide manufacturing inputs to factory master planning, including line layout, equipment placement, operator movement, material presentation, utility needs, ergonomics, safety, maintainability, and scalability.
Participate in design reviews and provide DFM/DFA feedback to improve manufacturability, assembly efficiency, serviceability, quality, and cost.
Define workstation-level requirements, including assembly sequence, operator interface, torque strategy, fastening methods, error-proofing, gauges, lifting devices, tools, jigs, fixtures, and production aids.
Support PFMEA, control plans, APQP/PPAP inputs, process validation, production trials, process audits, run-at-rate*** launch readiness reviews, and production handover activities.
Lead station readiness, tooling readiness, equipment readiness, Client readiness, material readiness, process documentation readiness, and quality readiness for new production lines.
Collaborate with Layout and Industrial Engineering teams to optimize line balance, operator movement, station design, material presentation, line-side storage, capacity, and production flow.
Work with Equipment and Controls Engineering teams to ensure equipment, fixtures, automation, sensors, HMI, safety systems, and process controls meet manufacturing requirements.
Support PFEP integration into manufacturing processes, including packaging strategy, sequencing, replenishment, point-of-use storage, line-side delivery, warehouse interfaces, and internal logistics.
Support equipment installation, commissioning, debug, process validation, run-at-rate*** ramp-up stabilization, and transition to stable operations.
Analyze production performance using OEE, cycle time, downtime, yield, scrap, rework, labor utilization, first-time quality, defect trends, and throughput data.
Lead root-cause analysis and corrective actions for issues related to process capability, line stoppages, quality defects, rework, scrap, ergonomics, equipment interaction, material flow, or operator efficiency.
Drive continuous improvement and cost reduction initiatives using lean manufacturing, Kaizen, 5S, VSM, SMED, Poka-Yoke, standardized work, waste elimination, and structured problem-solving methods.
Evaluate supplier manufacturing feasibility and provide technical inputs for outsourced parts, tooling, fixtures, equipment, and production readiness as required.
Basic Qualifications:
Bachelor's degree in manufacturing engineering, Mechanical Engineering, Industrial Engineering, Production Engineering, or related field.
7+ years of experience in manufacturing engineering, production launch, process development, industrialization, or manufacturing operations support.
Experience in large-scale manufacturing environments such as automotive, battery, energy, heavy equipment, aerospace, industrial equipment, or high-volume discrete manufacturing.
Strong understanding of manufacturing processes, production systems, tooling, fixtures, workstations, process documentation, and shop-floor execution.
Experience working with cross-functional teams across engineering, operations, quality, supply chain, equipment, controls, facilities, and EHS.
Preferred Qualifications:
Experience supporting greenfield manufacturing facility development, large-scale plant launch, or major capacity expansion programs.
Hands-on experience with production line launch, equipment installation, commissioning, run-at-rate*** ramp-up stabilization, and operational handover.
Strong knowledge of manufacturing processes such as machining, fabrication, welding, sheet metal, assembly, testing, surface treatment, painting/coating, and finishing.
Good understanding of engineering drawings, GD T, tolerance stack-up, BOM structure, material specifications, and manufacturing feasibility assessment.
Experience with PFMEA, control plans, APQP, PPAP, SPC, MSA, CAPA, 8D, process validation, production trials, process audits, and readiness reviews.
Strong knowledge of OEE, cycle time, takt time, line balancing, bottleneck analysis, yield improvement, scrap reduction, cost reduction, and throughput improvement.
Experience with PFEP, material flow, line-side delivery, packaging, sequencing, warehouse interfaces, and internal logistics.
Familiarity with MES, SCADA, Andon, OEE dashboards, traceability, ERP, PLM, SAP, Teamcenter, and manufacturing documentation control.
Familiarity with lean manufacturing, continuous improvement, root-cause analysis, 5 Why, Fishbone, Pareto, 5S, standardized work, visual management, and structured problem-solving.
Key Skills
Competencies:
Strong manufacturing process development and production launch capability.
Hands-on shop-floor mindset with the ability to translate engineering requirements into practical production solutions.
Ability to manage complex, cross-functional manufacturing issues from planning through execution.
Strong analytical and data-driven decision-making skills.
Excellent communication skills with the ability to influence stakeholders from shop floor to executive leadership.
Strong ownership mindset with focus on safety, quality, delivery, cost, productivity, and scalability.
Systems-thinking mindset with strong attention to detail.
Ability to work in a fast-paced, high-growth environment with multiple priorities, evolving requirements, and aggressive launch timelines.