Role Overview: The Advanced Manufacturing Engineer leads the development and implementation of manufacturing processes, capital equipment, automation, tooling interfaces, and production systems for thermoformed, polyurethane (PUR), foam-molded, and assembled products. Working across operations, quality, product development, tooling, maintenance, and external suppliers, this role industrializes new products and improves safety, quality, delivery, and cost.
Position Scope: This position translates product and business requirements into production-ready manufacturing solutions. Responsibilities span process concept development, equipment specification and sourcing, line layout, supplier management, installation, commissioning, validation, launch, and continuous improvement.
ESSENTIAL DUTIES AND RESPONSIBILITIES:New Product and Process Industrialization- Develop manufacturing concepts, process flows, equipment requirements, labor plans, capacity models, material-flow strategies, and line layouts for new products and programs.
- Support tooling Design for Manufacturability (DFM) reviews as the secondary manufacturing and industrialization representative, providing input on process requirements, equipment integration, production readiness, quality, capacity, and operational risk.
- Support the plant in planning and executing process trials, pilot builds, capability studies, run-at-rate activities, equipment validation, production-readiness reviews, and production launches.
Capital Equipment and Automation- Specify, source, justify, and implement capital equipment, automation systems, tooling-related equipment, and supporting utilities.
- Develop equipment Requests for Quotation (RFQs) and Statements of Work (SOWs) defining technical requirements, scope, deliverables, responsibilities, timing, acceptance criteria, and change-control requirements.
- Evaluate supplier proposals, prepare capital justifications and return-on-investment analyses, and manage machine builders, automation integrators, contractors, and equipment suppliers to approved scope, budget, and timing.
- Lead design reviews, factory and site acceptance testing (FAT/SAT), installation, commissioning, operator and maintenance training, run-off, and final equipment acceptance.
Manufacturing Technology and Process Ownership- Provide technical leadership for thermoforming and vacuum forming, PUR metering and dispensing, flexible and rigid foam molding, trimming, routing, bonding, robotic handling, vision inspection, and material handling systems.
- Define controls and automation requirements for PLCs, HMIs, robotics, servo systems, machine vision, sensors, safety systems, industrial networks, and equipment interfaces.
- Partner with maintenance, operations, and suppliers to resolve equipment, tooling, controls, utility, material, and process-performance issues.
- Establish and verify process windows, cycle times, capacity, quality controls, equipment performance targets, and Overall Equipment Effectiveness (OEE) requirements.
Production Support and Continuous Improvement- Provide hands-on engineering support during equipment launch, production ramp-up, process changes, and resolution of complex manufacturing issues.
- Monitor process capability and equipment performance; lead structured root-cause analysis and corrective actions for safety, quality, scrap, downtime, and throughput concerns.
- Improve OEE, throughput, labor efficiency, process capability, material utilization, ergonomics, and total manufacturing cost.
Documentation, Quality Systems and Compliance- Develop and maintain PFMEAs, control plans, process specifications, standard work, equipment documentation, spare-parts requirements, and preventive-maintenance inputs.
- Support APQP, PPAP, VDA, ISO, IATF, customer, and internal audit requirements applicable to assigned processes and launches.
- Complete or coordinate machine safety risk assessments and ensure equipment and processes comply with company safety requirements, applicable standards, and operational procedures.
Required Education and Experience- A bachelor's degree in Mechatronics Engineering, Electrical Engineering, Automation Engineering, Mechanical Engineering, or Manufacturing Engineering is required.
- A minimum of three years of experience in manufacturing engineering, advanced manufacturing, process engineering, automation engineering, equipment engineering, or new product launch is required. Candidates must have independently led capital-equipment or production-line projects from concept and specification through installation, validation, and production launch.
SUPERVISORY RESPONSIBILITIES: This position has no direct reports but provides technical leadership to cross-functional teams and directs the work of equipment suppliers, automation integrators, contractors, and other project resources.
REQUIRED QUALIFICATIONS:- Demonstrated ability to develop manufacturing processes and production systems from concept through validated launch and stable production.
- Experience specifying, sourcing, installing, commissioning, validating, and improving capital equipment and automated manufacturing systems.
- Clear written and verbal communication skills, with the ability to present technical information to plant teams, leadership, customers, machine builders, integrators, and suppliers.
- Ability to work independently, manage concurrent priorities, and lead cross-functional teams. Regular travel of approximately 40-60% is expected to support company plants, equipment suppliers, integrators, and customer locations.
- Working knowledge of Lean Manufacturing, Six Sigma, DOE, root-cause analysis, process capability, capacity analysis, and OEE.
- Ability to interpret product drawings, tooling designs, machine layouts, mechanical drawings, electrical schematics, fluid-power diagrams, technical specifications, and supplier proposals.
- Ability to develop capacity models, cycle-time analyses, equipment acceptance criteria, capital justifications, budgets, schedules, and technical reports.
- Strong project management, supplier management, organizational, and technical leadership skills.
- Proficiency with Microsoft Office applications, particularly Excel, and working knowledge of AutoCAD, SolidWorks, NX, or comparable CAD/layout tools.
PREFERRED QUALIFICATIONS:- Experience with thermoforming or vacuum forming equipment, trim systems, tool qualification, and thick-gauge thermoplastic processing.
- Experience with polyurethane (PUR), flexible or rigid foam molding, metering and dispensing systems, mold temperature control, and related process equipment.
- Experience with robotics, machine vision, PLC-controlled automation, safety systems, material handling, and equipment integration.
- Experience in automotive interiors, headliners, trim systems, NVH foam products, composites, plastics, or other high-volume manufacturing operations.
