Senior / Staff Manufacturing Engineer (NPI)

You will...

• Drive APQP Program Management at CM/Tier 1 sites, owning APQP to ensure a flawless Start of Production (SOP) and obtain PPAP deliverables.
• Design for Manufacturing (DFM) & Assembly (DFA): Provide design maturity feedback during APQP Phase 2, ensuring that the hardware can be built repeatedly with the CM’s specific tooling and equipment.
• Support Supplier Quality Engineering (SQE) by validating that component-level PPAPs from sub-tier vendors are integrated correctly into the CM’s assembly process.
• Be responsible for the mechanical assembly, test, and integration of sensors, compute, and actuation systems, defining the special characteristic (SC/CC) steps for the manufacturing process.
• Work closely with cross-functional teams to define, deploy, and validate End-of-Line (EOL) testers and calibration routines that confirm the "digital health" of the hardware.
• Lead the development of Process PPAP deliverables, including PFMEAs, Process Flow Diagrams, Control Plans, and Work Instructions ensuring the CM has identified and mitigated all assembly-related risks with "Poka-Yoke" (error-proofing) solution, and has established a robust manufacturing process.
• Design and qualify manufacturing equipment, tooling and gauges, ensuring that manufacturing process controls are in place. Providing assurance that GD&T and/or general specification and tolerance requirements are consistently met through MSA (Measurement Systems Analysis) and Gage R&R.
• Support Process Verification (PV) Testing, conducting "Run-at-Rate" studies to prove the manufacturing line can sustain quality targets at full production speed.
• Lead internal and CM-based RCCA (Root Cause Corrective Action) using the 8D methodology to resolve technical assembly failures during manufacturing.
• Manage Metrology and Measurement Systems Analysis (MSA), ensuring that all gauges and inspection fixtures at the CM are qualified via Gage R&R before production use.
• Collaborate with Field Quality teams to update manufacturing Control Plans based on real-world performance data and feedback from OEM partners.

Qualifications:

• Bachelors of Science in Mechanical Engineering or similar fields.
• NPI & CM Oversight Experience: Proven track record of launching automotive or high-tech hardware at Tier 1 or Contract Manufacturers using structured quality gates.
• Technical ownership of the launch cycle, specifically focusing on the transition from prototype to a production-validated manufacturing line.
• Advanced APQP & PPAP Management: Mastery of Control Plans, Process Flows, and Gage R&R, with a specific focus on manufacturing process stability (Cpk). Experience managing the transition from Design Verification (DV) to Process Verification (PV) and overseeing full PPAP submissions for complex electromechanical systems.
• Proficient with Solidworks for reviewing assembly fixtures, pallets, and inspection jigs.
• Expertise in GD&T & Metrology: Deep understanding of how to verify complex mechanical tolerances in a production environment using CMM, OMM, or vision systems.
• Problem-Solving Expert: Mastery of 8D and RCCA, with the ability to lead high-pressure technical resolution activities during a production ramp.
• Experience with PLM tools and document revision control to manage Engineering Change Orders (ECOs) and ensure BOM accuracy during the APQP cycle.
• Experience with various manufacturing processes such as precision torque, thermal interface material (TIM) dispensing, and high-stakes sensor calibration.
• Present manufacturing readiness to cross-functional teams, using data-driven insights to justify the move from APQP Phase 3 to Phase 4.

Bonus Qualifications:

• Automotive, Aerospace, Autonomous Vehicle (AV) or EV industry experience is highly preferred.
• IPC/WHMA-A-620 and IPC-A-610 knowledge for acceptance of wire harness assemblies and electronic assemblies.
• Experience with Robotic Workcells or automated assembly systems.
• Certified Quality Engineer (CQE) or Six Sigma Green/Black Belt.