JOB SUMMARY

The Senior Manufacturing Mechanical Engineer is responsible for leading and advancing Large Form Assembly (LFA) mechanical manufacturing operations by architecting, sustaining, and optimizing mechanical assembly processes. This role provides senior-level technical leadership in the development of mechanical work instructions, standard operating procedures (SOPs), Design for Assembly (DFA), and Design for Manufacturability (DFM) strategies specific to large, complex mechanical systems. The position serves as the mechanical manufacturing Subject Matter Expert (SME), ensuring structural integrity, production readiness, and process robustness across NPI, ramp, and sustaining phases. This role drives PFMEA development, mechanical risk assessments, tolerance stack-up analysis, and process validation while aligning engineering documentation with manufacturing execution to improve safety, quality, delivery, and cost performance.

ESSENTIAL DUTIES AND RESPONSIBILITIES

• Lead the development, review, and control of mechanical manufacturing documentation including work instructions, assembly drawings, exploded views, torque specifications, SOPs, bill of materials, and process flow documentation.
• Conduct DFM and DFA reviews during NPI to ensure mechanical designs are optimized for manufacturability, serviceability, ergonomics, and defect prevention.
• Develop, maintain, and update PFMEA documentation and structured risk assessments for mechanical assembly processes including structural, piping, and pressure-related systems.
• Define and standardize mechanical assembly methodologies including fastening strategies, torque validation, gasket and seal interfaces, alignment techniques, and workmanship standards.
• Analyze and manage tolerance stack-ups to prevent fit-up issues, interference conditions, leakage paths, and structural misalignment.
• Lead layout and installation strategy for mechanical subassemblies such as frames, enclosures, heat exchangers, piping, hoses, brackets, structural supports, and lifting interfaces.
• Break down complex mechanical drawings into simplified, trainable, production-ready work instructions to support multi-level operator capability.
• Develop and optimize mechanical build sequences to improve safety, ergonomics, takt time alignment, and overall labor efficiency (OLE).
• Partner with Industrial, Electrical, Controls, and Test Engineering to improve overall assembly flow, station balance, and cross-functional defect reduction.
• Provide advanced hands-on troubleshooting support for mechanical build issues including fit-up challenges, tolerance stack-ups, structural stress points, leak sources, vibration concerns, and rework drivers.
• Support equipment commissioning, FAT/SAT, and system acceptance activities related to mechanical integration and manufacturing readiness.
• Ensure controlled documentation and ECN discipline throughout NPI, ramp, and sustaining production phases.
• Lead continuous improvement initiatives focused on structural reliability, quality, safety, cost reduction, and mechanical process standardization.
• Identify and implement opportunities to improve mechanical robustness, reduce warranty risk, and lower total cost of ownership.
• Serve as escalation point and technical mentor for junior engineers and technicians within mechanical manufacturing operations.
• Maintain accurate and controlled mechanical documentation throughout NPI, production ramps, and sustaining phases.

EDUCATION & EXPERIENCE REQUIREMENTS

• Bachelor’s Degree in Mechanical Engineering, Manufacturing Engineering, or a related discipline.
• Minimum of 7 years of progressive experience in mechanical manufacturing, industrial equipment assembly, or related engineering roles.
• Demonstrated experience leading DFM/DFA initiatives and mechanical process optimization projects.
• Experience developing and maintaining PFMEA and mechanical risk mitigation documentation.
• Strong experience reading, reviewing, and interpreting mechanical drawings, GD&T, tolerance stack-ups, and complex assembly prints.
• Hands-on experience with structural builds, piping/hose routing, pressure interfaces, fastener strategies, and torque control systems.
• Experience developing structured manufacturing documentation including SOPs, standard work, and visual training aids.
• Working knowledge of applicable mechanical and safety standards (e.g., OSHA, ISO, ASME, torque and pressure safety practices).
• Experience supporting NPI launches, production ramps, and sustaining operations.

SPECIALIZED KNOWLEDGE / SKILLS

• Advanced understanding of large-form mechanical assembly methodologies and structural integration practices.
• Strong knowledge of GD&T application, tolerance analysis, and stack-up risk prevention in high-mix assemblies.
• Expertise in fastener selection, torque strategies, torque validation practices, gasket and sealing systems, hose and piping routing best practices, and structural alignment techniques.
• Strong knowledge of torque and fastener fundamentals, including clamp load, thread engagement, torque sequencing, joint integrity, and failure prevention.
• Hands-on knowledge of smart torque tools, including setup, programming, validation, data capture, traceability, and integration into standardized manufacturing processes.
• Experience creating and maintaining mechanical documentation using tools such as SolidWorks, AutoCAD, Creo, or equivalent CAD platforms.
• Familiarity with lifting strategies, fixturing, mechanical assembly aids, and ergonomic risk reduction methods.
• Experience supporting mechanical kitting strategies to improve material readiness and line-side efficiency.
• Strong understanding of mechanical failure modes including vibration, fatigue, stress concentration, leak paths, and pressure containment risks.
• Ability to identify and eliminate non-value-added steps in mechanical assembly processes using lean methodologies.
• Strong root cause analysis and structured problem-solving skills (8D, DMAIC, A3).
• Excellent cross-functional collaboration and communication skills in a fast-paced manufacturing environment.
• Ability to manage multiple priorities while providing technical leadership across programs and workcells.