Description

The Senior Manufacturing Engineer is responsible for defining, evaluating, and quoting manufacturing solutions for complex automotive assemblies, ranging from manual operations to fully integrated automated production systems. The role establishes the manufacturing approach and quotation assumptions for process flow, cycle time, equipment and tooling, capital investment, labor, floor space, capacity, and program timing.The position leads the development and integration of advanced, multi-station assembly systems incorporating robotics, automated material handling, controls, sensing, machine vision, in-line inspection and functional testing, traceability, data acquisition, and connectivity with plant production systems. The role establishes system architecture and performance requirements, manages technical and commercial risk, and leads selected solutions from concept and supplier development through validation, production launch, and continuous improvement.

Job Responsibilities
• Lead manufacturing feasibility and Design for Assembly (DFA) reviews for new products, engineering changes, transfers, and capacity expansions.
• Define the manufacturing and assembly strategy for complex products, including process flow, assembly sequence, level of automation, station architecture, component presentation, material flow, ergonomics, inspection, testing, traceability, and error-proofing.
• Develop process concepts, layouts, sequence-of-operation documents, cycle-time and line-balance models, labor and capacity requirements, equipment interfaces, preliminary capital requirements, and implementation plans.
• Develop and validate manual, semi-automated, and fully automated assembly processes; lead proof-of-concept trials and process studies to establish process windows, critical inputs, quality outputs, acceptance limits, and reaction plans.
• Own the technical integration between molding and downstream assembly, including automated insert presentation and loading, press-side automation, part conditioning and transfer, and coordinated material and data flow across connected operations, while molding-process development remains with the molding department.
• Evaluate manufacturing and automation technologies and recommend manual, assisted, semi-automated, or fully automated solutions based on safety, quality risk, complexity, product variation, volume, flexibility, maintainability, timing, and lifecycle cost.
• Prepare technical scopes of work, equipment specifications, RFQ packages, controls and data requirements, acceptance criteria, documentation requirements, and supplier deliverables for assembly equipment, automation, fixtures, and tooling.
• Lead supplier technical reviews and manage equipment suppliers through concept, design, build, factory acceptance, installation, site acceptance, capability studies, run-at-rate, and production handoff; manage risks, changes, timing, cost, and issue escalation.
• Lead the manufacturing-process and automation workstream for new program launches and major process changes, coordinating Engineering, Operations, Quality, Automation, Maintenance, Tooling, Molding, Purchasing, and external suppliers.
• Develop and execute process and equipment validation plans using measures such as safety compliance, cycle time, first-time capability, quality performance, OEE, uptime, MTBF, fault recovery, changeover, and run-at-rate results; confirm machine safety, ergonomics, maintainability, training, spare-parts, and maintenance readiness.
• Develop, complete, and maintain manufacturing documentation required for APQP and IATF 16949, including process flow diagrams, PFMEAs, control plans and inputs, error- and mistake-proofing (EMP) plans, workstation layouts, setup and process-parameter sheets, operator instructions, inspection and test requirements, capability and run-at-rate records, and engineering-change documentation.
• Lead higher-complexity continuous-improvement and problem-solving activities involving process redevelopment, automation upgrades, equipment reliability, cycle-time reduction, labor optimization, quality improvement, capacity, and material flow.
• Provide technical direction, design and document reviews, coaching, and mentoring to junior and plant-level Manufacturing Engineers; develop common standards, specifications, checklists, and lessons learned.

Requirements

Qualifications
• Bachelor's degree in Mechanical, Manufacturing, Mechatronics, Industrial, or related Engineering discipline; an Engineering Technology degree/diploma with substantial relevant experience may also be considered.
• Minimum 7 years of progressive Manufacturing Engineering experience, including responsibility for developing and implementing processes for complex assemblies in an automotive manufacturing environment.
• Experience in a plastic injection molding production environment is required, with strong knowledge of post-mold handling, automation, and assembly interfaces.
• Demonstrated experience developing and integrating complex, multi-station assembly systems involving robotics, automated material handling and component presentation, controls, machine vision and sensing, in-process inspection, functional testing, traceability, data acquisition, and error-proofing.
• Experience developing equipment specifications and RFQs and managing equipment suppliers from concept and design review through installation, validation, and production acceptance.
• Strong working knowledge of DFM/DFA, APQP, process flow, PFMEA, control plans, capability studies, run-at-rate, structured problem solving, and IATF 16949 requirements.
• Working knowledge of automation controls, robotics, vision, industrial networks, machine-safety systems, and equipment integration, with the ability to evaluate alternatives based on safety, technical risk, quality, lifecycle cost, timing, maintainability, flexibility, and capacity; direct programming capability is an asset.
• Proficiency with Microsoft Office and working capability with AutoCAD or comparable layout/design software; project scheduling and data-analysis tools are assets.
• Strong communication and technical-leadership skills, including the ability to manage multiple priorities, influence cross-functional teams, direct suppliers, present recommendations, mentor engineers, work independently, and travel as required.
• Working knowledge of the Ontario Occupational Health and Safety Act, machine-safety principles, ergonomics, and good manufacturing practices.