Job Description
Professional Summary (Enhanced with Automation)
Results-driven Manufacturing Engineer with strong expertise in manufacturing automation, continuous improvement, and new product introduction. Proven success in designing and implementing automated manufacturing processes and equipment that improve throughput, reduce waste, and enhance product quality. Skilled at leading cross-functional engineering teams, troubleshooting production issues, and driving lean manufacturing initiatives. Experienced in PLC-controlled equipment, robotics integration, and automated test systems while maintaining strict safety and quality standards.
Essential Duties and Responsibilities (with Automation Additions)
Essential Duties and Responsibilities include the following. Other duties may be assigned.
- Facilitate technical team meetings and project work, e.g., DFA, PFMEA, A3PS, data analysis, Design of Experiments, root cause analysis, Pugh analyses
- Coach and mentor new and existing engineers on processes, tools and skills required to further their personal development
- Work with Value Stream team to identify and apply continuous improvement methods to enhance manufacturing quality, reliability, or cost-effectiveness
- Design, plan, specify, procure, certify, and implement into production safe, high-quality, automated and semi-automated equipment and processes
- Develop and optimize automation strategies , including robotics, PLC programming, motion control, and machine vision to improve manufacturing efficiency and consistency
- Partners with Lean/CI team to develop manufacturing processes and standard work that improve output, reduce defects, improve product quality and reliability
- Benchmarks best manufacturing practices, automation technologies, and assembly techniques; introduces and implements enhanced automated processes that reduce cycle time and labor costs
- Functional ownership of item routings, work instructions, and process flow documentation, including automation process specifications and control plans
- Supports new product development, driving Design for Manufacturing/Assembly and Design for Automation objectives
- Support production equipment and processes as required to ensure optimal performance, including automation troubleshooting, PLC logic adjustments, and system upgrades
- Operations lead on New Product Introductions and Design Changes (ECN/ECR and OSK), including automation-ready process development
- Create efficient production processes to build and ship custom configured products within market lead time through automated workflow integration
- Review drawings, blueprints, sketches, manuals, or sample parts to determine appropriate manufacturing process; create drawings in SolidWorks or similar and integrate automation tooling
- Apply Lean Manufacturing practices, including line balancing, Kanban, 5S, SMED, and automation-driven waste reduction
- Create/Update information for creation of BOMs/Routings in ERP, including automation components and maintenance schedules
- Support Quality team on investigation and corrective action for product quality issues using automated testing and data collection systems
- Ability to work in a cross-functional team environment and drive results
- Ability to support other job functions (logistics, warehouse, technical sales, instrumentation) within a small team structure
- Ensure compliance with industry safety regulations and proactively implement automation safety systems (e-stops, light curtains, lockout/tagout)
- Collaborate with suppliers and system integrators to evaluate and implement automation equipment and digital manufacturing technologies
Skills
- Manufacturing Automation: PLC programming, robotics integration, machine vision systems, automated test stations, motion control
- Continuous Improvement: Lean manufacturing, Kaizen, 5S, Kanban, SMED, Value Stream Mapping (VSM), waste reduction
- Process Engineering: Assembly line design, process validation (IQ/OQ/PQ), Six Sigma methodologies, PFMEA, control plans
- Mechanical Design: Tooling and fixture design, GD&T, design for manufacturability/assembly (DFMA), SolidWorks
- Electrical/Controls: Ladder logic, HMI programming, servo systems, sensors & actuators, wiring schematics
- Project Leadership: Cross-functional collaboration, project planning, risk mitigation, supplier management, ERP/MRP systems
- Problem Solving: Root cause analysis (RCA), Design of Experiments (DOE), A3, 8D, statistical analysis
- Safety & Compliance: OSHA, CE/UL machine safety, lockout/tagout (LOTO), risk assessments
Tools & Technologies
- Automation & Controls: Allen-Bradley/Rockwell PLCs, Siemens PLCs, Omron, Mitsubishi, Schneider Electric
- Robotics: ABB, FANUC, Yaskawa Motoman, UR (Universal Robots), Kawasaki
- Vision & Sensors: Cognex, Keyence, Sick, Banner, Panasonic vision systems
- Motion Control: Allen-Bradley Kinetix, Bosch Rexroth, Festo, Parker Hannifin
- Manufacturing Software: AutoCAD, SolidWorks, Mastercam, ANSYS
- Data & Quality Tools: Minitab, JMP, SPC, MES systems
- Test & Measurement: NI LabVIEW, Fluke, National Instruments DAQ
- ERP Systems: SAP, Oracle, Infor, Epicor, Microsoft Dynamics
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