Description

Position Summary

The Production Engineer is responsible for optimizing manufacturing processes for transformer production, ensuring safety, quality, efficiency, and cost effectiveness. This role works closely with Operations, Quality, Maintenance, Supply Chain, and Design Engineering to support daily production, resolve technical issues, and drive continuous improvement across winding, core assembly, testing, and final assembly.

The ideal candidate brings strong hands-on manufacturing experience, problem-solving ability, and knowledge of transformer production principles.

Requirements

Key Responsibilities

Production Support & Process Optimization

• Support day to day production of transformer components, including coil winding, insulation, core building, welding, tank assembly, and electrical testing.

• Analyze workflow bottlenecks and implement process improvements to increase throughput and reduce scrap.

• Standardize work instructions, SOPs, and production documentation.

• Improve layout and material flow to optimize takt time and reduce non-value-added activity.

• Technical Troubleshooting

• Provide engineering support to resolve manufacturing issues related to winding, core clamping, insulation failures, vacuum/oil processing, or HV/LV assembly.

• Work closely with Design Engineering to interpret drawings, BOMs, and electrical schematics.

• Lead root-cause analysis (RCA) activities and corrective action plans (CAPA).

• Quality & Compliance

• Ensure production processes align with applicable industry standards (IEEE, ANSI, IEC).

• Partner with Quality to investigate defects, testing failures, and customer complaints.

• Maintain strong documentation practices and support internal/external audits.

• Continuous Improvement & Lean Manufacturing

• Lead Lean/Kaizen initiatives: 5S, waste reduction, value stream mapping, SMED, and standard work.

• Use data to drive decisions and track productivity, scrap rates, and cycle times.

• Identify opportunities for automation, fixture design, and equipment upgrades.

• Safety & Reliability

• Ensure compliance with safety regulations and implement engineering controls to reduce risk.

• Support electrical testing processes such as hipot testing, impulse testing, ratio verification, and insulation resistance.

• Cross-Functional Collaboration

• Partner with Maintenance on equipment troubleshooting, preventive maintenance, and new equipment commissioning.

• Work closely with Supply Chain to review BOMs, optimize materials usage, and improve inventory accuracy.

• Communicate production constraints or design feedback to Engineering and Leadership teams.

• Skills & Competencies

• Strong understanding of transformer manufacturing processes (distribution or power).

• Excellent analytical and troubleshooting skills.

• Familiarity with Lean Manufacturing principles and continuous improvement methodologies.

• Ability to read and interpret engineering drawings, electrical schematics, and technical specifications.

• Strong communication and teamwork across engineering, production, and leadership levels.

• Proficiency in Microsoft Office, CAD software, and ERP systems.

• Qualifications

• Bachelor’s degree in mechanical engineering, Electrical Engineering, Manufacturing Engineering, or related technical field.

• 3–5 years of engineering experience in transformer manufacturing or heavy electrical equipment preferred.

• Hands-on experience with coil winding, insulation design, core assembly, or testing is strongly desired.

• Knowledge of IEEE/ANSI/IEC transformer standards.

• Experience with Lean, Six Sigma, or CI tools (certifications preferred but not required).

• Working Conditions

• On-site role in a manufacturing environment.

• Exposure to production floor conditions (noise, machinery, oil processing equipment).

• Monday–Friday schedule with flexibility depending on production needs.

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