Position Summary
The Senior Manufacturing Engineer, Secondary Tooling is responsible for the technical leadership, development, sourcing, launch, and optimization of secondary tooling, assembly equipment, automation systems, and fixtures supporting new product launches and existing production operations. This position partners closely with Product Engineering, Manufacturing, Program Management, Suppliers, and Plant Operations to ensure manufacturing feasibility, cost competitiveness, quality performance, safety compliance, and successful program execution.
The role serves as the technical expert for secondary manufacturing processes and equipment, providing leadership in equipment specification, supplier management, commissioning, process validation, and continuous improvement activities across North American manufacturing facilities.
Essential Duties and Responsibilities
Program Launch Support
- Lead secondary tooling and equipment activities for new program launches from quotation through production.
- Develop equipment concepts, specifications, timing plans, and capital estimates.
- Support RFQ reviews, quoting activities, supplier selection, and sourcing decisions.
- Review product designs to ensure manufacturing feasibility and robust process implementation.
- Manage equipment build timing, budget, quality deliverables, and launch readiness.
- Support GDLS deliverables and tooling approval requirements.
Tooling and Equipment Management
- Manage design, fabrication, validation, and installation of secondary tooling and equipment.
- Coordinate machine runoffs, equipment buyoffs, and acceptance testing activities.
- Oversee supplier performance to ensure program objectives related to timing, cost, safety, and quality are achieved.
- Review tooling concepts and engineering changes for technical soundness and cost impact.
- Support commissioning activities and equipment qualification trials.
Manufacturing Process Development
- Develop and optimize manufacturing processes to improve efficiency, throughput, quality, and ergonomics.
- Establish process standards and equipment requirements in alignment with corporate manufacturing standards.
- Support process validation activities and PPAP readiness.
- Analyze process capability and identify opportunities for continuous improvement.
- Drive OEE improvements and cycle time optimization initiatives.
Plant and Production Support
- Provide technical support to manufacturing facilities during launch and production.
- Troubleshoot equipment, tooling, automation, and process-related issues.
- Assist plants in resolving quality, productivity, safety, and reliability concerns.
- Support emergency tooling and equipment recovery activities as needed.
- Travel to manufacturing facilities to support launch activities and significant production issues.
Supplier Development and Technical Leadership
- Interface directly with tooling suppliers, automation integrators, OEM customers, and internal stakeholders.
- Conduct design reviews and technical assessments of equipment concepts.
- Review supplier deliverables including tooling designs, timing plans, validation documentation, and cost submissions.
- Provide technical mentoring and guidance to engineering and manufacturing teams.
- Drive adoption of best practices and standardization across manufacturing facilities.
Technical Expertise
Experience should include several of the following manufacturing technologies:
- Heat staking
- Ultrasonic welding
- Hot plate welding
- Infrared welding
- Punching and trimming systems
- Edge wrapping
- Vacuum forming
- Assembly fixtures
- Robotic work cells
- Vision inspection systems
- Torque and fastening systems
- PLC-controlled manufacturing equipment
- Automated material handling systems
Qualifications
Education
- Bachelor's Degree in Manufacturing Engineering, Mechanical Engineering, Industrial Engineering, Automation Engineering, or related technical discipline required.
Experience
- 7-10+ years of manufacturing engineering, tooling engineering, automation, or process engineering experience.
- Experience supporting Tier 1 automotive manufacturing environments.
- Demonstrated experience managing tooling and equipment launches from concept through production.
- Experience working with interior automotive products preferred, including instrument panels, center consoles, door panels, and hard trim components.
- Experience managing external tooling and automation suppliers.
Preferred Qualifications
- Experience with Allen-Bradley and/or Siemens controls platforms.
- Knowledge of manufacturing automation and industrial controls.
- Understanding of PPAP, APQP, GD&T, PFMEA, and manufacturing launch processes.
- Project management experience within a multi-plant environment.
- Manufacturing Process Expertise
- Tooling & Equipment Development
- Program Launch Management
- Technical Problem Solving
- Supplier Management
- Continuous Improvement
- Cost Management
- Project Leadership
- Cross-Functional Collaboration
- Communication and Influence
- Customer Focus
- Safety Leadership
Travel
- Ability to travel domestically and internationally, including facilities and suppliers throughout the United States, Mexico, and Canada.
- Estimated travel requirement: 20-30%.