Senior Plant Accountant

The Manufacturing Engineer – Advanced Manufacturing & Process Optimization person plays a critical, hands-on role in developing, implementing, and continuously improving the manufacturing processes that support both our customers and our employee-owners. This position goes far beyond maintaining existing workflows—our engineers are deeply involved in analyzing production systems, optimizing material and information flow, driving equipment utilization improvements, and ensuring that all processes meet stringent cost, quality, and throughput objectives.

You will partner closely with Production Supervisors, Quality, Engineering, Maintenance, and Supply Chain across multiple plants and shifts, working within a culture committed to Lean principles, structured problem-solving, and data-driven decision-making. Success in this role requires the ability to assess complex production challenges, propose engineered solutions, justify capital improvements, and lead cross-functional implementation efforts from concept through validation.

Primary Responsibilities

Process Engineering, Optimization & Technical Leadership

• Develop, implement, and refine robust manufacturing methods that support repeatability, standardization, and scalable production performance.

• Analyze existing workflows and equipment capabilities using structured tools such as time studies, method engineering, production simulations, and statistical process control (SPC).

• Own the creation, update, and lifecycle management of routings, work instructions, tooling specifications, and engineering blueprints to ensure accuracy, manufacturability, and alignment with customer specifications.

• Serve as the technical subject-matter expert on process capability and control limits (Cp, Cpk, Pp, Ppk), using these metrics to drive quality improvements and evaluate incoming work packages.

Lean Systems, Continuous Improvement, and Problem Solving

• Lead structured problem-solving efforts using tools such as fishbone diagrams, 5 Why analysis, FMEA, value stream mapping (VSM), job safety analysis (JSA), and 6S/5S methodologies.

• Identify bottlenecks, waste, and inefficiencies, and champion Kaizen events aligned to cycle time reduction, scrap elimination, throughput optimization, and operator ergonomics.

• Utilize discrete-event simulation or digital manufacturing models to evaluate proposed process changes and validate improvements before implementation.

• Partner with production teams to build a culture of continuous improvement through coaching, training, and hands-on guidance.

Manufacturing Data, ERP/MRP, and Cost Engineering

• Maintain and optimize routing structures, bills of materials (BOMs), labor standards, and capacity models within the company's ERP/MRP system to ensure accuracy of cost estimates and production planning.

• Analyze shop floor data to develop data-backed improvement roadmaps and operational KPIs such as OEE, cycle time, yield, and labor efficiency.

• Develop financial justifications and ROI analyses for new equipment, automation initiatives, tooling upgrades, or layout changes.

Advanced Manufacturing Tools & Technology Application

• Utilize CAD/CAM software (SolidWorks or equivalent) to design and evaluate fixtures, tooling, and process aids that support efficient and repeatable manufacturing operations.

• Apply advanced GD&T (Geometric Dimensioning & Tolerancing) to ensure manufacturability and maintain conformance in dimensional-critical production environments.

• Engage with Maintenance and Equipment Engineering teams to improve equipment uptime, capability, and preventive/predictive maintenance processes.

• Contribute to plant layout optimization, material flow design, line balancing, and workstation ergonomics to support long-term operational scaling.

Cross-Functional Collaboration & Multi-Site Support

• Provide plant-floor technical guidance, operator training, and troubleshooting support to ensure processes are executed safely, correctly, and efficiently.

• Work across all three plants and multiple shifts to maintain a high level of engineering support for production, new program launches, and continuous improvement activities.

• Collaborate with Supply Chain, Quality, and outside vendors to resolve technical issues, qualify materials, improve manufacturability, and enhance supplier performance.

Qualifications

Required Education & Experience

• Bachelor's degree in Manufacturing Engineering, Industrial Engineering, Mechanical Engineering, Engineering Technology, or related field (or equivalent experience).

• Minimum 3 years of hands-on manufacturing or metals industry experience, including exposure to machining, fabrication, forming, welding, assembly, or related processes.

• Demonstrated experience in industrial engineering methods, project management, and manufacturing process development.

• Proficiency with SolidWorks or equivalent CAD/CAM packages; strong understanding and application of GD&T standards.

• Strong ability to communicate complex technical information to production teams, engineering colleagues, vendors, and customers.

• Advanced mechanical aptitude and strong quantitative skills, including applied statistics and data interpretation.

• High proficiency in Microsoft Office applications including Excel (advanced formulas, pivot tables, charts), PowerPoint, Word, and Project.

Preferred Skills

• 5+ years of engineering experience in a manufacturing or metals-based environment.

• Proven track record improving OEE, reducing scrap, or driving measurable operational improvement.

• Deep knowledge of Lean tools: VSM, Kanban, Kaizen, Visual Factory, 6S, SMED, Poka-Yoke, and waste reduction techniques.

• Experience developing time standards, performing line balancing, and designing plant/facility layouts.

• Familiarity with quality systems such as ISO 9001, AS9100, or IATF 16949, including control plans, PPAP, or process audits.

• Hands-on experience with ERP or MRP systems (e.g., SAP, Epicor, Oracle Netsuite, Infor, Microsoft Dynamics), including routing and BOM management.

• Understanding of materials flow, inventory control concepts, and production scheduling logic.