Sr AME Fabrication Engineer

The Senior Advanced Manufacturing Engineer is responsible for leading the development, implementation, and optimization of manufacturing processes, equipment, and production systems to support new product introductions (NPI), plant transfers, capacity expansion, automation, and continuous improvement initiatives. This role provides technical leadership across cross-functional teams and drives improvements in safety, quality, cost, delivery, and productivity. Responsibilities align with Advanced Manufacturing Engineering activities including process design, capital equipment implementation, manufacturing readiness, and operational excellence. 

Key Responsibilities

• Lead manufacturing process design and validation for new products.
• Develop manufacturing routings, work instructions, Bills of Process, and production standards.
• Define tooling, fixtures, handling equipment, and automation solutions.
• Support Design for Manufacturing (DFM) and Design for Assembly (DFA) reviews.
• Establish process parameters and acceptance criteria.

New Product Introduction (NPI)

• Lead manufacturing readiness activities through APQP and NPDI gates.
• Coordinate prototype, pilot, and production builds.
• Conduct process risk assessments including PFMEA.
• Support PPAP submissions and product launch activities.
• Ensure manufacturing deliverables are completed on schedule.

Capital Equipment & Automation

• Identify and justify advanced manufacturing technologies.
• Develop capital expenditure requests and ROI analyses.
• Lead equipment procurement, installation, validation, and startup.
• Implement automation, robotics, vision systems, and productivity improvements.

Continuous Improvement

• Lead Lean Manufacturing and Six Sigma initiatives.
• Improve productivity, throughput, quality, and material utilization.
• Reduce labor costs, scrap, rework, and process variation.
• Drive standardization across manufacturing sites.

Project Leadership

• Manage multiple projects simultaneously.
• Coordinate activities between Design Engineering, Quality, Operations, Supply Chain, and Maintenance.
• Track project milestones, risks, budgets, and deliverables.
• Provide technical leadership and mentoring to engineers and technicians.

Manufacturing Support

• Resolve complex production and quality issues.
• Conduct root cause analysis and corrective actions.
• Support plant transfers and capacity expansions.
• Serve as technical advisor for manufacturing operations. 

Required Qualifications Education

• Bachelor's degree in Mechanical Engineering, Industrial Engineering, Manufacturing Engineering, Mechatronics, or related field.

Experience

• 7+ years of manufacturing engineering experience.
• 3+ years supporting NPI or APQP projects.
• Experience leading capital equipment or automation projects.
• Experience in sheet metal fabrication, assembly, thermal products, or related manufacturing environments preferred.

Technical Skills

• APQP, PFMEA, Control Plans, PPAP.
• Lean Manufacturing and Six Sigma methodologies.
• Process capability studies (Cp, Cpk, Pp, Ppk).
• Statistical Process Control (SPC) and MSA.
• Manufacturing cost analysis.
• CAD systems and equipment layout development.
• Project management tools and ERP systems.
• Automation, robotics, PLCs, or vision systems preferred. 

Leadership Competencies

• Strong project leadership.
• Cross-functional collaboration.
• Technical problem-solving.
• Data-driven decision making.
• Effective communication with global teams and suppliers.
• Mentoring and development of junior engineers.

Key Performance Indicators (KPIs)

• NPI launch performance.
• Productivity improvement.
• Cost savings realization.
• FPY / RTY improvement.
• Scrap and rework reduction.
• Capital project execution.
• Manufacturing readiness achievement.
• Safety and quality performance.