Shift: 1st Shift

Working days: Mon - Fri

Working hours:

SUMMARY

The Sr. Industrial Engineer provides senior-level technical leadership and strategic oversight for manufacturing system design and optimization within assigned workcells, supporting complex large-form assemblies (LFA) and integrated system-level products. This role is responsible for architecting scalable production systems, leading Design for Manufacturability (DFM) and Design for Assembly (DFA) initiatives, driving facility readiness, conducting PFMEA and formal risk assessments, and ensuring operational efficiency, cost control, safety, and capacity alignment.

The Sr. Industrial Engineer leads industrialization efforts from quoting through NPI and full production ramp, ensuring labor models, ergonomics, facility infrastructure, material flow, and digital systems are aligned to support safety, quality, delivery, and margin objectives. This role mentors engineering staff influences cross-functional stakeholders, and ensures manufacturing systems meet internal standards, regulatory requirements, and business objectives.

ESSENTIAL DUTIES AND RESPONSIBILITIES include the following. Other duties may be assigned.

LEADERSHIP AND MANAGEMENT RESPONSIBILITIES

Recruitment and Retention:

· Recruit and interview Industrial Engineers and Manufacturing Engineers.

· Communicate criteria to recruiters for Sr. Industrial Engineer candidates.

· Coach engineers in structured problem solving, PFMEA methodology, and risk-based decision making.

· Monitor team member turnover; identify key factors that can be improved; implement retention improvements.

Employee and Team Development:

· Identify individual and team strengths and development needs on an ongoing basis.

· Create and/or validate industrial engineering training curriculum in work measurement, labor modeling, ergonomics, PFMEA, and risk mitigation.

· Develop and maintain training aligned to LFA manufacturing environments and advanced facility design.

· Mentor engineers to design safe, ergonomic, scalable, and financially optimized production systems.

Performance Management:

· Establish clear, measurable goals tied to productivity, labor efficiency, ergonomic risk reduction, floor space optimization, yield performance, and safety metrics.

· Solicit ongoing feedback from Engineering Management, Workcell Managers (WCM), Business Unit Director (BUD), peers, and team members.

· Provide ongoing coaching and counseling based on KPI performance and risk exposure.

· Establish measurable goals tied to cost reduction, throughput, risk mitigation, and NPI readiness.

· Drive continuous improvement in operational, safety, and ergonomic KPIs.

· Coordinate engineering execution during launches, facility modifications, capacity expansions, or production escalations.

Communication:

· Provide a communication forum for the exchange of ideas and information within the department and cross-functional teams.

· Present risk assessments, PFMEA results, and mitigation strategies clearly to leadership.

· Encourage input from team members during risk reviews and process design sessions.

· Adapt communication style to diverse audiences including Operations, Facilities, Quality, and Executive Leadership.

SUPERVISORY RESPONSIBILITIES

Business Strategy and Direction:

· Understand campus strategic direction and growth roadmap.

· Define and implement industrial engineering strategies that integrate risk-based decision making into manufacturing system design.

· Ensure facility and layout strategies support long-term scalability, safety compliance, and ergonomic sustainability.

· Provide regular updates to Engineering Leadership on risk posture, mitigation actions, and system robustness.

Cost Management:

· Identify creative ways to reduce cost by streamlining processes, reducing ergonomic strain, and eliminating non-value-added activity.

· Lead cost-avoidance initiatives through early risk identification and mitigation.

· Drive cost-down initiatives through DFA/DFM collaboration and PFMEA-driven improvements.

· Utilize analytical tools to monitor departmental cost, safety trends, and productivity performance.

TECHNICAL MANAGEMENT RESPONSIBILITIES

· Serve as Lead Industrial Engineer for assigned workcells and programs.

· Architect scalable manufacturing systems for large mechanical and electrical assemblies.

· Lead comprehensive PFMEA activities to identify process risks, failure modes, and control gaps prior to launch and during sustaining production.

· Conduct formal risk assessments for new equipment, layout changes, process modifications, and facility upgrades.

· Develop mitigation strategies to reduce operational, safety, quality, and capacity risks.

· Lead ergonomic assessments including:

• Repetitive motion analysis

• Lifting and load evaluations

• Reach zone optimization

• Workstation height and adjustability validation

• Fatigue reduction strategies

• Compliance with ergonomic standards and best practices

· Lead end-to-end facility layout development for entire facilities, including production flow, workcell design, warehouse integration, receiving, shipping, PFEP, supermarket strategy, staging, detrash, material flow, and future expansion planning.

· Support building and infrastructure modifications including:

• Utility capacity planning (power, air, water, drainage)

• Pit and foundation requirements

• Structural modifications impacting production flow

• Equipment footprint and heavy material handling paths

· Lead Design for Manufacturability (DFM) and Design for Assembly (DFA) reviews during NPI.

· Drive part count reduction, assembly simplification, ergonomic risk mitigation, and process standardization.

· Develop advanced labor models incorporating takt time, efficiency, yield, and demand variability.

· Own time studies, work measurement systems, and labor standards validation.

· Develop, build, and maintain robust capacity models supporting shift strategy, equipment planning, labor requirements, throughput analysis, and long-term growth planning.

· Identify bottlenecks and implement data-driven corrective actions.

· Lead layout simulations and material flow optimization studies.

· Develop and maintain Plan for Every Part (PFEP) models to define part flow, packaging, replenishment methods, storage locations, line-side presentation, delivery frequency, material handling equipment, and inventory control requirements.

· Support quoting activities with detailed labor, facility, and risk-based cost analysis.

· Partner with Manufacturing Engineering, Quality, Facilities, EHS, and Operations to deploy safe and scalable production systems.

· Enforce adherence to EHS, safety, and risk mitigation policies across all industrial engineering activities.

MINIMUM REQUIREMENTS

Bachelor’s degree in Industrial Engineering, Civil Engineering, or related technical discipline required. Ten (10) or more years of progressive experience in manufacturing system design, PFMEA leadership, risk assessment execution, ergonomic analysis, industrialization, capacity model development, PFEP development, and full-facility layout planning within complex assembly environments. Demonstrated experience with large-form assemblies, DFA/DFM leadership, facility layout redesign, labor modeling, material flow optimization, and cross-functional project execution. Proven ability to lead measurable safety improvements, risk reduction initiatives, and financial performance gains. Must be able to obtain and maintain all required job-related certifications.