Lead Manufacturing Process Engineer

2 weeks ago

Carlisle, Massachusetts, United States BigBelly Solar Full time

We are looking for a Lead Manufacturing Process Engineer to become a vital part of our Operations Team at Bigbelly Solar. This role is crucial as we advance our innovative product initiatives, and it offers a prominent, cross-functional opportunity within the organization as we enhance our internal manufacturing and development capabilities.

In this position, you will be responsible for the design, execution, and enhancement of manufacturing processes and systems. This role requires close collaboration with both domestic and international production teams to ensure our products are manufactured efficiently, safely, and in accordance with established quality standards. You will take the lead on projects aimed at resolving production challenges, creating process documentation, and implementing cost-reduction strategies. Additionally, you will partner with the Development Engineering team to integrate new technologies and products into our manufacturing facilities. Ideally, you possess experience in both manufacturing and development settings, having successfully transitioned multiple products into production while managing their lifecycle. A strong background in working with supply chain teams and fostering relationships with global suppliers and production partners is essential.

This role reports directly to the Plant Operations Manager and is responsible for providing the necessary methodologies and processes to empower the production team to excel in Quality, Execution, Cost, Flexibility, and Process Innovation.

Key Responsibilities

Safety Management

  • Promote strict adherence to safety protocols throughout the operation to safeguard yourself and your colleagues from harm.
  • Ensure that all manufacturing equipment (including jigs, fixtures, material handling tools, etc.) is designed and utilized safely.
  • Assist the Plant Manager in enforcing common safety practices on a daily basis.

Cost Optimization

  • Utilize Lean methodologies to initiate and lead projects that enhance manufacturing cost-efficiency by improving manufacturability, reducing touch time, and optimizing part flow and packaging. Conduct regular Gemba walks.
  • Collaborate with the supply chain team to identify and evaluate alternative sources for cost improvements.
  • Analyze labor time for tasks to maintain accurate labor schedules, consistently seeking time reductions.
  • Participate in the evaluation of the Direct Labor competency matrix as a member of the assessment board.

Design and Implementation

  • Work alongside Engineering and suppliers to ensure the manufacturability of new products using DFX, PFMEA, DFMEA, GD&T, and tolerance analysis.
  • Oversee the installation and commissioning of new equipment and processes to support New Product Introduction (NPI).
  • Lead the development of new manufacturing processes, systems, and technologies to enhance Bigbelly's operational capabilities.
  • Coordinate collaborative project builds with Engineering when production equipment is required.

Troubleshooting and Problem Resolution

  • Provide engineering support to production teams to address technical challenges.
  • Assist in analyzing field failures and in-process quality issues.
  • Support the resolution of quality concerns through root cause analysis and the implementation of preventive corrective actions.

Documentation Management

  • Assist in the creation and maintenance of manufacturing work instructions and process control plans for all products, ensuring the appropriate tools are in place for conveying instructions and recording results.
  • Coordinate requests for engineering changes, leading the implementation of Engineering Change Orders (ECOs) at suppliers and in-house production.

Project Leadership and Management

  • Lead mid to high-level manufacturing projects, providing direction, guidance, and engineering expertise to team members while delivering formal presentations to leadership regarding project status, including resource plans, timelines, and budgets.
  • Develop and maintain plans for new tooling, equipment, and production capabilities.

Qualifications

  • Bachelor's degree in Manufacturing, Industrial, or Mechanical Engineering.
  • 10+ years of experience in an electromechanical manufacturing environment.
  • Strong leadership and management capabilities.
  • Excellent problem-solving and analytical skills, with a preference for statistical experiment design experience.
  • Familiarity with Lean Manufacturing and Six Sigma DMAIC methodologies; Greenbelt certification is preferred.
  • Experience with SolidWorks 3D CAD design software is desirable.
  • Proficiency in using PLM tools, preferably Arena.
  • Lean-Six Sigma Greenbelt certification utilizing DMAIC principles is a plus.
  • Strong understanding and proficiency in GD&T.

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