The Staff Manufacturing Engineer is a senior technical leader responsible for driving New Product Introduction (NPI), manufacturing industrialization, process development, automation, and continuous improvement initiatives for Power Cable Assembly and electrical interconnection products.

This role leads the development and launch of manufacturing processes, equipment, and automation solutions from concept through mass production, ensuring safe, efficient, scalable, and high-quality manufacturing operations. The position requires strong expertise in cable assembly processes, ultrasonic welding, process validation, equipment development, and manufacturing excellence within high-volume production environments.

• Lead NPI and manufacturing industrialization activities from product concept through production launch and ramp-up.
• Develop manufacturing processes, equipment specifications, production layouts, capacity models, and industrialization plans.
• Drive equipment installation, commissioning, qualification, FAT/SAT, acceptance, and production readiness activities.
• Identify manufacturing risks and implement mitigation plans to support successful product launches.
• Partner closely with Product Engineering, Quality, Operations, Supply Chain, and Program Management teams.

Manufacturing Process Expertise

• Cable cutting and preparation.
• Wire stripping and insulation removal.
• Terminal crimping and crimp validation.
• Connector and power cable assembly.
• High-current cable applications.
• Mechanical assembly processes.

Ultrasonic Welding

• Develop and optimize welding processes and parameters.
• Validate weld quality, process capability, and repeatability.
• Troubleshoot welding defects through root-cause analysis.
• Improve equipment performance and process robustness.

Process Validation & Quality

• Develop and maintain Process Flows, PFMEAs, Control Plans, Work Instructions, and process specifications.
• Execute DOE, MSA/GR&R, capability studies, and Cp/Cpk analysis.
• Establish process windows and validate equipment performance.
• Ensure processes meet quality, cycle time, capacity, and uptime targets.

Equipment Development

• Develop equipment specifications and technical requirements.
• Lead equipment design reviews and supplier interactions.
• Support equipment build, debugging, qualification, and final acceptance.

Continuous Improvement

• Drive productivity and labor-efficiency improvements.
• Reduce scrap and manufacturing costs.
• Identify automation opportunities.
• Improve process performance, quality, and operational efficiency.