Manufacturing Engineer

The Manufacturing Engineer is a high-visibility, hands-on role responsible for establishing stable, capable, and efficient manufacturing processes across assigned product value streams in a new program production start-up environment. Reporting directly to the Plant Manager, this role will take ownership of stabilizing end-to-end manufacturing processes for multiple products during plant ramp-up. The engineer will drive process capability, reduce variation, and implement structured root cause solutions while serving as the primary technical owner for customer quality issue resolution.

This is a highly empowered role with direct impact on product quality, cost, and delivery performance, requiring strong technical ownership and the ability to operate effectively in a fast-paced, evolving production environment.

What You’ll Do

New Value Stream Process Stabilization Ownership (Immediate Focus)

• Establish and own end-to-end manufacturing process performance for assigned product value streams including following operations:
  • Injection molding
  • Automated fabric cutting
  • Adhesive application (roll coating and spray)
  • Lamination and edge folding of interior trim components
• Establish stable, repeatable, and capable processes across all steps of the value stream
• Lead process development, setup, startup, and troubleshooting activities
• Maintain and evolve Control Plans and PFMEA tied to actual process risks
• Maintain and evolve process related quality documentation
• Optimize process parameters to reach stable levels of scrap, yield, cycle time, and throughput
• Identify and eliminate sources of variation across interconnected processes
• Drive process standardization and define “golden parameters” for each operation
• Collaborate with tooling, design, and production teams to improve manufacturability

Integrated Customer Quality Responsibilities

• Serve as primary technical owner for customer quality issues
• Lead structured root cause analysis using 8D or equivalent methodologies
• Define and implement containment, corrective, and preventive actions
• Validate effectiveness of corrective actions using process and product data
• Communicate technical findings and resolution status to internal teams and customers
• Ensure timely and professional response to customer concerns
• Plan and execute process validations (IQ/OQ/PQ) across multiple manufacturing steps
• Design and execute DOE studies to establish robust process windows
• Perform process capability analysis (Cp/Cpk) for critical characteristics
• Ensure alignment between process parameters and product performance requirements

Quality System Development Support

• Support implementation of quality systems aligned with ISO 9001 and IATF 16949
• Implement SPC on critical process and product characteristics
• Lead measurement system analysis (MSA) activities where required
• Contribute to internal audit readiness and continuous improvement initiatives

Continuous Improvement & Operational Excellence (After Stabilization)

• Control and streamline mass production (man, machine, material, method, environment) variables and own consequent in-house as well as customer concerns
• Drive scrap reduction, cost reduction, and efficiency improvement initiatives
• Improve process flow and integration across value stream operations
• Support development of visual controls, standard work, and process documentation
• Train and guide technicians and operators on process control and problem-solving
• Identify opportunities for automation and process enhancement

What You’ll Bring

• Bachelor’s degree in Mechanical, Manufacturing, Plastics, Chemical, or Industrial Engineering (or equivalent experience)
• 3-5+ years of hands-on manufacturing process engineering experience
• Demonstrated experience in structured problem-solving in technical manufacturing processes
• Experience in one or more of the following strongly preferred:
  • Injection molding
  • Adhesive processes / coating / lamination
  • Textile or trim component manufacturing
• Experience with process validation, troubleshooting, and production ramp environments
• Working knowledge of automotive quality methodologies (PPAP, APQP, FMEA, SPC, MSA, Control Plans)

• Strong process engineering mindset across multi-step manufacturing systems
• Ability to understand and control variation across interconnected processes
• Strong communication skills for cross-functional and customer interaction
• Strong problem-prevention mindset
• Strong root cause analysis and data-driven decision-making skills
• Working knowledge of SPC and process capability concepts
• Ability to operate effectively in a fast-paced, evolving production environment
• Proficiency in MS Office (Excel, Word, PowerPoint); ERP/SAP experience a plus
• Working knowledge of 2D and 3D CAD tools highly desirable
• High ownership mindset with ability to independently drive results, prior results in start up environment a plus

Work Environment

• Combination of production floor and office work; significant time on manufacturing floor required
• Requires standing, walking, and lifting up to 50 lbs as needed
• PPE compliance required in production areas
• Flexible schedule to support production ramp, trials, and issue resolution
• Fast-paced startup environment with competing priorities

Physical requirements for this role include being able to lift 25 – 40 lbs, walking, standing, bending, reaching, pushing, pulling, grasping parts, operating a keyboard (not an all-inclusive list).