Senior Mechanical Engineer – Continuous Improvement for Mechanical Design & Quality Control

Job Overview

Do you have a knack for design of complex mechanical systems? Have you ever invented a tool or changed a process just to make routine installation or service faster and easier? If you're driven by solving real-world design challenges, especially within state of the art mechanical power generation equipment, then this role is built for you.

Mainspring Energy is seeking a Continuous Improvement Engineer with a focus on mechanical design to lead product improvement efforts across our field and production systems. You will work on-site at a contract manufacturer, addressing design and manufacturing issues at their root. You will redesign critical components for durability and ease of service, integrate your findings back into the development process to ensure the long-term reliability and manufacturability of our products.  You will support manufacturing with a hands-on approach to solve complex mechanical problems working directly with the product to take measurement, perform testing, and support pilot efforts to develop rework/retrofit processes.

You will redesign critical components for durability and ease of service, and integrate your findings back into the development process to ensure the long-term reliability and manufacturability of our products.  

Responsibilities

Lead the root cause analysis of mechanical failures using data from diagnostics, hands-on testing, and fundamental analysis of bolted joints or material fatigue life
Redesign or re-engineer components, fasteners, or assemblies to eliminate failures, reduce costs, or improve serviceability
Work closely with design engineering, manufacturing, and quality teams to ensure that changes are thoroughly tested and validated with short feedback cycles
Collaborate with NPI, manufacturing quality, and supply chain teams to ensure solutions are optimized for production, vendor capabilities, and field service
Predict and prevent failure modes by applying a deep understanding of mechanical system interactions, tolerance stack-ups, and real-world use conditions
Implement feedback loops from field issues into design standards and engineering processes to continuously improve product quality and reduce recurrence
Create and manage internal improvement systems that embed learnings into manufacturing process flow and future design development efforts
Support the development of service tooling, testing fixtures, or diagnostic aids as needed for improved deployment and serviceability
Travel to HQ in Menlo Park, CA required once per quarter

Qualifications

BS + 6 years, or MS + 5 years in industry roles with a focus on mechanical design
Hands-on experience with mechanical design, including analysis of bolted joints, stress analysis, and structural integrity
Proven ability to use data-driven root cause analysis to solve complex, cross-functional design issues
Experience addressing and resolving field and production issues
Knowledge of DFM/DFA principles and quality system tools (PFMEA, 8D, CAPA, etc.)
Deep understanding of tolerance stack-ups and the use of CMMs in inspection processes
Familiar with manufacturing processes including tube swaging, crimping, potting, stamping, sheet metal, hydroforming, welding, machining, and fabrication
Proficient in SolidWorks or a comparable CAD package; PDM experience preferred
Experience with structural FEA and/or is a plus
A passion for building robust, field-ready solutions with high reliability and serviceability