Manufacturing Engineer - Headliners Department
Position Overview
The Manufacturing Engineer is responsible for designing, developing, implementing, and continuously improving manufacturing processes within a Tier 1 automotive supplier environment. This role focuses on optimizing production methods, improving equipment performance, increasing operational efficiency, and supporting the successful launch of new products and engineering changes. The Manufacturing Engineer serves as a key technical resource for production operations, helping to ensure safety, quality, delivery, and cost objectives are achieved while maintaining compliance with customer and company requirements.
Duties and Responsibilities
- Design, develop, and maintain efficient manufacturing processes to support production requirements and customer specifications.
- Evaluate and improve production methods, equipment layouts, material flow, and workstation design to maximize productivity and reduce waste.
- Identify opportunities for process improvements and implement solutions that enhance safety, quality, efficiency, and overall equipment effectiveness (OEE).
- Develop and maintain manufacturing documentation, including process flows, work instructions, and standard operating procedures.
- Support plant continuous improvement initiatives through Lean Manufacturing and problem-solving activities.
- Analyze manufacturing operations and provide technical support to resolve production challenges.
- Determine equipment, tooling, fixtures, and material requirements needed to achieve production goals and product specifications.
- Monitor and improve production performance through process optimization, capacity analysis, and workflow improvements.
- Support equipment installation, process validation, and production readiness activities.
- Lead troubleshooting efforts related to manufacturing processes, equipment performance, and production issues.
- Perform root cause analysis on product defects, process failures, downtime events, and customer concerns.
- Develop, implement, and validate corrective and preventive actions to improve process reliability and product quality.
- Partner with Quality, Production, and Maintenance teams to reduce scrap, rework, and non-conforming product.
- Coordinate and implement manufacturing changes introduced by Product Engineering and Launch Engineering teams.
- Support new product launches, engineering changes, equipment validation, and production trials.
- Evaluate process feasibility and ensure manufacturing readiness for new products and program changes.
- Assist in the development and implementation of process controls to meet customer and production requirements.
- Provide engineering support for manufacturing technologies, including PLC-controlled equipment, robotics, welding systems, and automated assembly processes.
- Work closely with Maintenance, Controls Engineering, and Production teams to improve equipment uptime, reliability, and performance.
- Collaborate with Production, Quality, Maintenance, Supply Chain, and Engineering teams to achieve plant objectives.
- Participate in APQP activities, PFMEA reviews, Control Plan development, and process validation efforts.
- Support compliance with customer-specific requirements, safety standards, and automotive industry quality systems.
- Lead and participate in continuous improvement and cost-reduction initiatives.
Education and Experience Requirements
- Bachelor's Degree in Manufacturing Engineering, Mechanical Engineering, Industrial Engineering, or a related engineering discipline required.
- Minimum of 3 years of experience in a manufacturing engineering role within a high-volume manufacturing environment.
- Experience supporting automotive manufacturing operations, preferably within a Tier 1 supplier environment.
- Experience with process development, equipment implementation, production support, and continuous improvement initiatives.
- Demonstrated experience in troubleshooting manufacturing processes and implementing corrective actions.
Preferred Qualifications
- Experience with Headliner manufacturing processes, including Thermoforming, Water Jet trimming, Edge Folding, and Edge Wrapping operations, is strongly preferred.
- Experience with automotive quality systems and core tools, including APQP, PPAP, PFMEA, MSA, and Control Plans.
- Knowledge of Lean Manufacturing, Six Sigma, Kaizen, and continuous improvement methodologies.
- Experience working with PLC-controlled equipment, robotics, welding systems, and industrial automation technologies.
- Familiarity with automated assembly processes and secondary equipment operations.
- Strong root cause analysis, problem-solving, and project management skills.
- Proficiency with Microsoft Office applications and manufacturing-related software.
- Excellent communication and interpersonal skills with the ability to work effectively in a cross-functional environment.
- Ability to manage multiple projects and priorities in a fast-paced manufacturing setting.
Physical Requirements
- Ability to work in a manufacturing environment with regular exposure to production equipment, automation systems, and varying noise levels.
- Ability to stand, walk, bend, and move throughout the manufacturing facility for extended periods.
- Ability to occasionally lift and carry up to 25 pounds.
- Ability to observe, evaluate, and troubleshoot manufacturing processes on the production floor.
- Ability to wear required personal protective equipment (PPE) and comply with all safety requirements.