Director of Equipment Engineering - Premier PV (Dallas)

Job Title: Director of Equipment Engineering & Maintenance (Greenfield)Department: Operations / Manufacturing EngineeringReports To: VP of Operations / Site LeaderPosition SummaryThe Director of Equipment Engineering & Maintenance will lead the design, build, and ramp of all manufacturing equipment, automation systems, and maintenance operations for a greenfield, high-volume eBOS production facility.This role is responsible for establishing a world-class, scalable manufacturing platform to produce combiner boxes, cable assemblies, and overmolded harnesses. The Director will define equipment standards, build maintenance systems from the ground up, and ensure rapid, reliable production ramp with best-in-class uptime, quality, and cost performance.This is a hands-on leadership role requiring deep technical expertise and the ability to operate effectively in a fast-paced startup environment within a large-scale industrial build.Key Responsibilities Greenfield Facility Build & RampLead equipment engineering and maintenance strategy from concept through full production ramp.Partner with design/construction teams on:Facility layout and line designUtilities (power distribution, compressed air, cooling, resin handling systems)Equipment footprint, flow, and scalabilityDefine manufacturing line architectures for:Combiner box assemblyCable and harness productionOvermolding operationsSupport installation, commissioning, and vertical ramp to high-volume production. Equipment Engineering Strategy & DeploymentDevelop standardized, scalable equipment platforms across all production lines.Specify, source, and qualify manufacturing equipment including:Automated and semi-automated assembly systemsWire processing and crimping equipmentInjection molding and overmolding systemsLead equipment validation (FAT, SAT, IQ/OQ/PQ).Ensure design-for-manufacturing (DFM) alignment with product and R&D teams.Establish engineering documentation, standards, and change control systems. Maintenance System Build-OutBuild the maintenance organization from the ground up, including hiring, training, and structuring teams.Implement and deploy a CMMS for asset management, work orders, and spare parts control.Establish:Preventive maintenance programsPredictive/condition-based maintenance systemsSpare parts strategy and inventory optimizationDrive early equipment reliability through commissioning and ramp phases.Embed Total Productive Maintenance (TPM) culture across operations. Process & Equipment OwnershipOversee equipment performance across key processes:Combiner BoxesAutomated fastening, busbar assembly, enclosure handlingElectrical test systems (hipot, continuity, insulation resistance)Cable & HarnessesCutting, stripping, crimping, sealing, routingCrimp force monitoring and pull testingOvermolded HarnessesInjection molding presses, tooling, and auxiliary systemsMaterial drying, handling, and process controlEnsure process capability, repeatability, and robust error-proofing (poka-yoke).Standardize equipment and processes for multi-line replication. Automation, Controls & Digital InfrastructureDefine and implement plant-wide automation architecture:PLCs, HMIs, SCADARobotics and automated assembly cellsVision inspection systemsDeploy Industry 4.0 systems:Real-time equipment monitoringData collection and analyticsMES integration and full product traceabilityEnsure cybersecurity and system reliability from day one. Capital Projects & Vendor ManagementOwn multi-million-dollar CapEx planning and execution for equipment and tooling.Select and manage OEMs, integrators, and tooling suppliers.Drive project execution from concept through commissioning and ramp.Ensure all projects meet timeline, budget, and performance targets. Reliability & Operational ExcellenceEstablish and track key performance metrics:OEE, uptime, MTBF, MTTRLead structured root cause analysis (RCA) and CAPA processes.Drive continuous improvement in:ThroughputChangeover time (SMED)Scrap reduction (especially crimping and overmolding defects)Build a data-driven reliability engineering function. Quality, Safety & ComplianceEnsure compliance with:OSHA, NFPA safety standardsUL and NEC requirements for eBOS productsISO 9001 / ISO 14001 systemsImplement safe equipment design and maintenance practices (LOTO, arc flash).Support audits, validation (IQ/OQ/PQ), and quality systems from startup phase.Champion a zero-incident safety culture. New Product Introduction (NPI)Build scalable equipment solutions for new combiner box and harness designs.Partner with R&D to ensure seamless transition from prototype to production.Enable rapid product launches without disrupting ramp.QualificationsEducationBachelor’s degree in Mechanical Engineering, Electrical Engineering, Manufacturing Engineering, or related field (Master’s preferred).Experience12–15+ years in manufacturing engineering, equipment engineering, or maintenance.7–10+ years leading engineering and maintenance teams.Direct experience with greenfield or brownfield plant startups strongly preferred.Strong background in:Wire harness / cable assembly manufacturingInjection molding / overmoldingHigh-volume automated manufacturing environmentsTechnical ExpertiseEquipment design and industrial automation systemsWire processing, crimping, and termination technologiesInjection molding machines, tooling, and polymersPLCs, robotics, vision systems, and SCADAReliability engineering, CMMS, TPMLean manufacturing and Six SigmaLeadership CompetenciesProven ability to build teams, systems, and processes from zero to scaleStrong project and program management capabilityHands-on, execution-oriented leadership styleExcellent cross-functional communication and stakeholder alignmentData-driven decision-making mindsetKey Performance Indicators (KPIs)Ramp-to-volume timeline achievementOEE and uptime during ramp and steady-state productionMTBF / MTTR improvementsCapEx delivery (on time, on budget, on performance)Scrap and yield performance (especially overmolding and crimping)Maintenance cost efficiencySafety metrics (TRIR, near misses)Work EnvironmentGreenfield construction and startup environment transitioning to high-volume manufacturingSignificant time on the production floor and during equipment installation phasesCollaboration with global vendors, contractors, and internal teamsTravel RequirementsUp to 30% travel for:Equipment supplier selection and design reviewsFactory Acceptance Testing (FAT) at OEM sitesBenchmarking across other facilitiesSupporting multi-site standardization as the network scalesJob SummaryRequisition Number: DIREC021621Job Category: EngineeringSchedule: Full-Time