Staff Manufacturing Engineer

The Staff Manufacturing Engineer provides technical leadership and advanced engineering support throughout the product lifecycle, from product design and development through manufacturing release and production. The role is responsible for improving product manufacturability, resolving complex mechanical and production issues, supporting First Article Inspection (FAI), evaluating alternative parts, and enhancing manufacturing capabilities.

The position also leads engineering support for supplier qualification and outsourced manufacturing, drives Non-Conformance and continuous improvement initiatives, and ensures the development and maintenance of engineering and quality documentation in support of ISO 9001 and other applicable requirements. Working closely with cross-functional teams, the Staff Manufacturing Engineer drives improvements in quality, productivity, cycle time, cost, and overall operational performance.

Key Responsibilities

• Lead and support the development of products from the design stage through manufacturing release and full-scale production.
• Review, develop, and improve product designs based on customer requirements, product specifications, manufacturability, quality, reliability, and cost considerations.
• Provide technical leadership and engineering support to resolve complex mechanical, product, manufacturing, and production-related issues in a timely and effective manner.
• Review, create, maintain, and improve technical drawings, specifications, cut-lists, labels, and other engineering documentation to ensure accuracy, completeness, and timely availability for production.
• Drive product and design improvements throughout the product lifecycle to enhance manufacturability, product performance, quality, reliability, and operational efficiency.
• Support and lead Engineering First Article Inspection (FAI) activities and drive improvements in FAI release capacity, quality, and turnaround time.
• Conduct Manufacturing Capability Assessments and work with internal teams and suppliers to improve assessment turnaround time and manufacturing readiness.
• Evaluate alternative parts proposed by Buyers or through SPS/PR requests, including assessment of technical compatibility, quality, manufacturability, cost, and potential impact on product performance and production.
• Address and resolve production-related engineering issues involving labels, cut-lists, fittings, component compatibility, drawings, and other technical matters within established turnaround time targets.
• Lead and support the qualification, technical assessment, and onboarding of new outsource suppliers, including evaluation of their manufacturing capabilities, processes, quality systems, and technical readiness.
• Provide engineering support to outsource suppliers and internal manufacturing teams to resolve technical, product, process, and quality-related issues.
• Lead and participate in Non-Conformance (NC) investigations and improvement projects involving internal production operations and outsource suppliers.
• Apply structured problem-solving methodologies to identify root causes, implement corrective and preventive actions, and prevent recurrence of manufacturing and quality issues.
• Develop, review, implement, and maintain engineering and manufacturing documentation in support of ISO 9001 and other applicable quality management system requirements, including Work Instructions, OCAP, FMEA, Control Plans, Process Flows, and related procedures and records.
• Support internal and external audits, address engineering-related findings, and ensure timely implementation and sustainability of corrective actions.
• Lead continuous improvement initiatives to enhance engineering efficiency, manufacturing capability, product quality, cycle time, productivity, and cost performance.
• Analyze engineering and operational data to identify trends, recurring issues, risks, and opportunities for process and performance improvement.
• Lead or participate in cross-functional projects involving new product introduction, product transfers, design changes, manufacturing process improvements, supplier development, and capacity expansion.
• Prepare and present weekly and monthly engineering reports covering project status, operational performance, technical issues, improvement initiatives, and key engineering metrics.
• Provide technical guidance and mentorship to engineers, technicians, and other relevant team members.
• Work closely with Product Engineering, Manufacturing, Quality, Supply Chain, Procurement, and external suppliers to ensure effective execution and timely resolution of engineering matters.
• Perform other duties and responsibilities as assigned by Management.

Requirements:

• Bachelor's Degree in Mechanical, Manufacturing, Industrial, Mechatronics, Electrical, Electronics, or related Engineering discipline.
• Minimum 8–10 years of relevant experience in Manufacturing Engineering, Process Engineering, or a related role within a manufacturing environment.
• Strong technical knowledge of manufacturing processes, process development, equipment, tooling, and production systems.
• Demonstrated experience leading complex technical projects and cross-functional improvement initiatives.
• Strong knowledge and practical application of Lean Manufacturing, Six Sigma, Kaizen, DOE, SPC, PFMEA, 8D, and other problem-solving methodologies.
• Experience in NPI, product transfer, process validation, equipment qualification, or manufacturing automation is an advantage.
• Strong analytical, problem-solving, project management, and decision-making skills.
• Able to influence and work effectively with stakeholders across different functions and organizational levels.
• Excellent communication and interpersonal skills.
• Demonstrated leadership capability, with the ability to coach and mentor junior engineers.
• High level of ownership, accountability, initiative, and continuous improvement mindset