Senior Manufacturing Engineer

· Develop and validate manual, semi-automated, and fully automated assembly processes; lead proof-of-concept trials and process studies to establish process windows, critical inputs, quality outputs, acceptance limits, and reaction plans.

· Own the technical integration between molding and downstream assembly, including automated insert presentation and loading, press-side automation, part conditioning and transfer, and coordinated material and data flow across connected operations, while molding-process development remains with the molding department.

· Evaluate manufacturing and automation technologies and recommend manual, assisted, semi-automated, or fully automated solutions based on safety, quality risk, complexity, product variation, volume, flexibility, maintainability, timing, and lifecycle cost.

· Prepare technical scopes of work, equipment specifications, RFQ packages, controls and data requirements, acceptance criteria, documentation requirements, and supplier deliverables for assembly equipment, automation, fixtures, and tooling.

· Lead supplier technical reviews and manage equipment suppliers through concept, design, build, factory acceptance, installation, site acceptance, capability studies, run-at-rate, and production handoff; manage risks, changes, timing, cost, and issue escalation.

· Lead the manufacturing-process and automation workstream for new program launches and major process changes, coordinating Engineering, Operations, Quality, Automation, Maintenance, Tooling, Molding, Purchasing, and external suppliers.

· Develop and execute process and equipment validation plans using measures such as safety compliance, cycle time, first-time capability, quality performance, OEE, uptime, MTBF, fault recovery, changeover, and run-at-rate results; confirm machine safety, ergonomics, maintainability, training, spare-parts, and maintenance readiness.

· Develop, complete, and maintain manufacturing documentation required for APQP and IATF 16949, including process flow diagrams, PFMEAs, control plans and inputs, error- and mistake-proofing (EMP) plans, workstation layouts, setup and process-parameter sheets, operator instructions, inspection and test requirements, capability and run-at-rate records, and engineering-change documentation.

· Lead higher-complexity continuous-improvement and problem-solving activities involving process redevelopment, automation upgrades, equipment reliability, cycle-time reduction, labor optimization, quality improvement, capacity, and material flow.

· Provide technical direction, design and document reviews, coaching, and mentoring to junior and plant-level Manufacturing Engineers; develop common standards, specifications, checklists, and lessons learned.