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Senior Process Engineer
2 months ago
About the Company
Berkner Group collaborates with a pioneering manufacturer specializing in electrolyzer stack technology. Backed by prominent investors, this organization is dedicated to providing innovative solutions for the production of cost-effective electrolyzers, utilizing entirely domestic supply chains. Their cutting-edge technology, based on an anion exchange membrane (AEM), employs readily available materials such as steel and plastic, eliminating the reliance on rare earth elements prevalent in current technologies. By integrating advanced manufacturing methodologies from related high-tech sectors, this company significantly reduces the manufacturing costs of electrolyzer stacks.
Position Title: Senior Manufacturing Engineer
Location: Lowell, MA
Department: Manufacturing
FLSA Status: ☒ Exempt ☐ Non-exempt
Position Purpose
This role is essential for the development and validation of manufacturing methodologies and equipment necessary for producing components and complete stack assemblies for advanced electrolyzer products.
Key Responsibilities
- Design and implement efficient manufacturing processes and machinery for the fabrication of electrolyzer cell components and stack assembly, accommodating both low-volume manual and high-volume automated production methods.
- Collaborate with suppliers to ensure timely delivery of equipment.
- Conduct Design for Manufacturability and Assembly analyses.
- Oversee the design, construction, installation, and validation of component processing equipment, assembly fixtures, and related tools.
- Develop and maintain comprehensive process documentation, including Process Flow Documents, PFMEAs, BOMs, and ECNs.
- Maintain an updated equipment status and issue tracking list, along with capital budget oversight.
- Provide progress reports to management and promptly escalate unresolved issues.
- Analyze and troubleshoot equipment and production challenges.
Expected Outcomes
Area: Prototype Fabrication
Weight: 20%
Deliverable: Successful planning and execution of prototype builds with effective follow-up on issue resolution.
Area: Process Development and Validation
Weight: 25%
Deliverable: Creation of suitable manufacturing processes to fulfill production capacity and quality standards, with thorough documentation of procedures and results.
Area: Production Equipment Specification, Design, and Launch
Weight: 30%
Deliverable: Formulation and release of detailed equipment specifications for vendor RFP/RFQ processes, along with oversight of installation and launch on the production floor.
Area: Standard Operating Procedures
Weight: 15%
Deliverable: Preparation and release of effective process documentation, including Process Flow Charts, Station Layouts, and Operator Instructions.
Area: Supplier Engagement
Weight: 10%
Deliverable: Initiation and follow-up on activities with current and potential equipment vendors.
Qualifications
Education
- Bachelor's degree in Mechanical or Electrical Engineering (required)
- Master's degree (preferred)
Work Experience
- A minimum of 10 years of relevant, hands-on experience in a manufacturing or manufacturing development setting.
Skills & Abilities
- Proficiency in English.
- Practical skills in hardware assembly, testing, and related tasks.
- Expertise in identifying and resolving system faults, along with root-cause analysis.
- Familiarity with needs assessment, specification development, verification planning, and testing.
- Experience with SolidWorks and PLC programming is advantageous.
- Background in Automation Design/Build is a plus.
- Knowledge of 3D printing technologies is desirable.
- Experience with laser cutting techniques for metals and plastics is beneficial.
Work Environment
This position involves working in development, manufacturing, and office environments, emphasizing hands-on tasks primarily in a manufacturing or pilot plant setting. A five-day in-office schedule is expected.
Travel Requirements
Domestic and international travel, including overnight stays, may be required up to 15% of the time.