Senior Manufacturing Engineer

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Position: Senior Manufacturing Engineer

Reports to: Director, Lithium & Manufacturing Engineering

Location: Lithonia,GA

Date:

Position Overview

Trojan Battery Company is seeking a Senior Manufacturing Engineer to join our team in a high-growth, innovation-driven manufacturing environment. This role is responsible for leading process design, automation, and continuous improvement initiatives, with a strong emphasis on PLC-controlled manufacturing systems, equipment reliability, and process capability.

The Senior Manufacturing Engineer serves as a technical leader and problem solver, providing direction to cross-functional teams, mentoring junior engineers, and driving capital projects that improve safety, quality, throughput, and cost. This position plays a key role in advancing automation, controls robustness, and data-driven manufacturing performance across the plant.

The ideal candidate is hands-on, technically strong, and comfortable working on the manufacturing floor while also leading strategic initiatives and capital investments.

Areas of Focus

• Lead and support automation-driven process improvements using PLC-controlled equipment

• Drive process stability, equipment uptime, and yield improvements through controls optimization and root-cause analysis

• Act as a technical escalation point for complex process and equipment issues

Key Responsibilities

Process & Manufacturing Engineering

• Lead the identification, definition, and control of critical process parameters including machine logic, interlocks, alarms, and safety systems

• Troubleshoot complex quality, scrap, throughput, and downtime issues using structured problem-solving methods (A3, 5-Why, Fishbone, DOE)

• Improve process capability through statistical analysis and control of key variables

• Apply Lean Manufacturing principles (Takt Time, SMED, Poka-Yoke, Kanban, Kaizen, 6S, TPM)

• Establish and maintain safe, ergonomic, and compliant manufacturing processes

PLC & Automation (Allen-Bradley)

• Provide senior-level troubleshooting support for Allen-Bradley PLC-controlled equipment (ControlLogix / CompactLogix)

• Diagnose PLC logic, I/O, sensors, VFDs, servos, interlocks, alarms, and fault conditions

• Collaborate with Maintenance, Controls Engineers, and OEMs to resolve recurring automation issues

• Support HMI diagnostics, alarm rationalization, and operator interface improvements

• Participate in PLC change reviews, FAT/SAT activities, and documentation updates

• Utilize PLC data to improve OEE, availability, and downtime reduction

Maintenance, Reliability & Capital Projects

• Lead improvements in corrective, preventive, and predictive maintenance strategies

• Define automation and equipment standards for new capital equipment

• Lead vendor and system integrator technical evaluations

• Own assigned capital project budgets, schedules, and execution from concept through startup

• Ensure projects are delivered safely, on time, and on budget

Documentation, Compliance & Leadership

• Prepare and maintain engineering documentation including Process Flow Diagrams, pFMEAs, Control Plans, SOPs, Job Element Sheets, time studies, capacity analysis, and capital requests

• Ensure compliance with ISO-9001, machine safety standards, and regulatory requirements

• Mentor Manufacturing Engineers and technicians

• Partner with Operations, Quality, EHS, Maintenance, and Supply Chain teams

Basic Qualifications

• 5–8+ years of experience in manufacturing with automated and PLC-controlled equipment

• Bachelor’s degree in Electrical, Electronic, Mechanical, or Electro-Mechanical Engineering

• Experience in battery manufacturing, preferably lead-acid

• Hands-on experience troubleshooting Allen-Bradley PLC systems

• Strong understanding of industrial automation components

• Capital project management experience

• Strong analytical, financial, and problem-solving skills

• Proficiency in Microsoft Office, AutoCAD, and statistical software

• Excellent technical documentation skills

• Ability to support off-shift troubleshooting as needed

• Occasional travel required

Preferred Qualifications

• Experience with OEE systems, MES integration, or PLC data extraction

• Exposure to industrial networking (EtherNet/IP)

• Six Sigma Green or Black Belt

if you like wild growth and working with happy, enthusiastic over-achievers, you'll enjoy your career with us!