OVERVIEW

As a member of the Manufacturing Team, the Manufacturing Engineer/Automation will lead the design, development and continuous improvement and analysis of the manufacturing operations.  The Senior Manufacturing Engineer  is accountable for providing scientific and engineering specialization, technical support, design support, testing support and development support for system manufacturing processes.  Also, She/He will optimize automation and high flow manufacturing delivering product/process performance, quality, efficiency and cost.

ESSENTIAL RESPONSIBILITIES

• Taking ownership, complete end-to-end planning of the manufacturing equipment layout, including launch of new equipment


• Work with OEM to conceptualize, design, develop and optimize equipment for automated production and manufacturing


• Responsible for user specification documentation explaining and streamlining the whole validation task


• Successful compilation and execution of the installation qualification (IQ), Operational Qualification (OQ), and Performance Qualification (PQ)


• Create trace-ability matrix for process validation


• Perform Design of Experiment (DOE) as needed


• Data capture in SQL Database for each production process


• Understand and use statistical tools for Statistical Process Control (SPC)


• Shepard the design, work closely with our partners to build and test an automated production line of equipment through Factory Acceptance Testing (FAT)


• Administer an inspection and dynamic testing of systems or major system components to support the qualification and validation of equipment in US manufacturing locations


• Verify the installed functionality of the equipment meets or exceeds the operational requirements as specified in the equipment User Requirement Specification (URS)


• Execute a Site Acceptance Test (SAT) on completion of all commissioning tasks; but prior to the start of Installation qualification execution.


• Continually improve on % yield, increase throughput, reduce downtime, increase quality


• Partner closely with engineering teams during all phases of development and product introduction


• Participate in Design for Manufacturing (DFM), Failure Mode and Effects Analysis (FMEA) reviews/provide feedback


• Drive manufacturing, test and assembly process related technical and operational issues to ensure issue closure


• Create preventative maintenance plans, schedules, and checklists, critical tooling / parts list and specifications.


• Participate and assist the Quality & EHS teams in the development of Working Instructions, Job Safety Analysis and other Operation documents


• Review all equipment requirement plans, along with assessment of the robustness of solution to meet operation requirement and implementation of any additional solutions to mitigate any risks to plans


• Drive new manufacturing process development process review and approval


• Successfully sample, debug, and qualify new complex prototype/production tools


• Lead in product design, material selections, and tooling reviews


• Lead manufacturing in troubleshooting processes out of specifications


• Take action to assure confidentiality of Company’s proprietary equipment, materials, and processes.

ADDITIONAL RESPONSIBILITIES

• Develop improvements of workplace / workstation design


• Initiates and evaluates project requests through cost justification analysis


• Evaluates opportunities for efficient utilization and cost reduction, presenting solutions to continually improve overall production system performance


• Establishes and implements a process to prioritize projects within the plant based on economic returns


• Assist in the quotation process of new projects, including production tooling requirements and the cost of assembly


• Confer with vendors to arrange for the purchase of equipment, tooling and materials


• Use a combination of testing methods including automation


• Coordinate and supervise testing activities


• Lead the design and review of programmable logic


• Collaborate with engineers to achieve expected quality levels in products


• Create presentations and present projects to senior management for discussion and approval


• Provide written status reports to senior management and expedite project timelines


• Influence the inclusion of test-ability during design and development phases


• Ensure compliance of quality processes and standards

KNOWLEDGE, SKILLS AND ABILITIES

• Familiar with design of experiment (DOE) & process capability (CPK)


• Familiar with Statistical Process Control (SPC) & statistical data analysis


• Knowledge of Matlab & Minitab


• Ability to  troubleshoot PLC’s and robotics


• Skilled in High flow & high volume manufacturing


• Strong troubleshooting and problem-solving skills


• Strong communication and documentation skills


• Strong verbal and written communication skills


• Ability to anticipate and head problems “off-at-the-pass”


• Time management, organizational and multi-tasking skills necessary to work in a fast-paced environment, handling various tasks and changing priorities


• High attention to detail and accuracy to achieve daily assignments and goals


• Ability to make engineering judgment decisions


• Demonstrated hands on problem solving utilizing good engineering principles


• Six Sigma Black Belt with strong Lean manufacturing experience


• Experience with Six Sigma, Lean Manufacturing & ABS as well as statistical analysis methods is ideal.

REQUIRED EDUCATION AND EXPERIENCE

• BS in Industrial Engineering or similar background


• 7+  years’ experience in manufacturing process development, machine / equipment bring-up


• Direct experience in manufacturing process design, review and buy off


• OSHA Safety standards, knowledge and certifications 

DESIRED EXPERIENCE

• Battery or power related experience a plus


• Supplier management experience is a plus.


• Project Management in Manufacturing is a plus

TRAVEL

Position is based in Edison, NJ with 20% travel to China, 20% travel to Manufacturing sites, equipment manufacturers and suppliers as needed.