The Advanced Manufacturing Engineer is responsible for developing, planning, and launching manufacturing processes for automotive seating products. This role supports new program launches by designing efficient manufacturing systems, optimizing production processes, and ensuring safety, quality, cost, and delivery objectives are achieved. The engineer collaborates with cross-functional teams including Product Engineering, Quality, Production, Purchasing, and suppliers to deliver robust manufacturing solutions.
Responsibilities- Lead manufacturing process development for new seating programs from concept through production launch.
- Develop manufacturing process flows, work instructions, PFMEA, control plans, and standardized work documentation.
- Design and implement assembly processes for seat structures, foam, trim, mechanisms, and final seat assembly.
- Specify, source, and validate manufacturing equipment, tooling, fixtures, and automation systems.
- Coordinate equipment installation, commissioning, runoff, and production readiness activities.
- Conduct process capability studies and ensure manufacturing processes meet customer quality requirements.
- Support APQP activities, including Process Flow Diagrams, PFMEA, Control Plans, Run-at-Rate, and PPAP submissions.
- Drive continuous improvement initiatives focused on safety, quality, productivity, and cost reduction.
- Analyze manufacturing data to identify opportunities for process optimization and waste elimination.
- Support ergonomic assessments and implement improvements to reduce operator fatigue and improve workplace safety.
- Collaborate with suppliers to ensure tooling and equipment meet technical specifications and project timelines.
- Participate in Design for Manufacturability (DFM) reviews during product development.
- Troubleshoot manufacturing issues during prototype, pilot, and production phases.
- Manage manufacturing engineering timelines, budgets, and deliverables.
- Ensure compliance with customer specifications, IATF 16949, ISO 14001, and company standards.
Qualifications- Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, or a related technical descipline.
- 5+ years of manufacturing engineering experience in automotive manufacturing, preferably seating or interior systems.
- Experience supporting new product launches from concept through production.
- Knowledge of APQP, PPAP, PFMEA, Control plans, MSA, and SPC.
- Experience with Lean Manufacturing and Six Sigma methodologies.
- Strong understanding of assembly processes, ergonomics, and industrial engineering principles.
- Experience with automated assembly equipment, robotics, and poka-yoke systems.
- Proficiency with CAD software (CATIA, SolidWorks, AutoCAD, or similar).
- Strong project management and problem-solving skills.
- Excellent communication and cross-functional collaboration abilities.
Preferred- Experience in automotive seating manufacturing.
- Knowledge of seat structures, recliners, tracks, foam, trim, and seat assembly operations.
- Familiarity with PLCs, industrial controls, vision systems, and automation integration.
- Green Belt or Black Belt Six Sigma certification.
- Experience with Industry 4.0 technologies, MES systems, and data analytics.
- Familiarity with ergonomic assessment tools and time studies.
Technical Skills- APQP/PPAP
- PFMEA/DFMEA
- Process Flow Development
- Control Plans
- Lean Manufacturing
- Six Sigma
- Root Cause Analysis (8D, 5 Why, Fishbone)
- Value Stream Mapping
- Industrial Engineering
- Robotics & Automation
- Ergonomic Analysis
- CAD software
- Microsoft Office Suite
- Project Management
Core Competencies- Manufacturing process development
- Continuous improvement mindset
- Technical problem solving
- Project leadership
- Team collaboration
- Attention to detail
- Customer focus
- Results orientation
- Decision making
- Time management
Physical Requirements- Ability to work in both office and manufacturing environments.
- Ability to stand and walk on the production floor for extended periods.
- Occasional lifting of up to 25 lbs.
- Ability to travel up to 20% to suppliers and customer locations as required.
Key Performance Indicators (KPIs)- Successful launch of new seating programs
- Achievement of launch timing milestones
- First-pass yield and process capability (CP/CPK)
- Equipment uptime and OEE improvements
- Manufacturing Cost reduction
- Scrap and rework reduction
- Safety performance
- Continuous improvement project completion
- Customer quality performance (PPM)
