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Lead Manufacturing Process Engineer

2 months ago

Lawrence, Kansas, United States Big Belly Solar LLC Full time

Big Belly Solar LLC is on the lookout for a Lead Manufacturing Process Engineer to become an integral part of our Operations Team. As we embark on an ambitious product journey, this role is crucial in fostering collaboration across various functions while enhancing our internal manufacturing and development capabilities.

In this position, you will be responsible for designing, executing, and refining manufacturing processes and systems. This entails close collaboration with both domestic and international production teams to ensure our products are manufactured efficiently, safely, and in accordance with established quality benchmarks. You will take the lead on projects aimed at troubleshooting production challenges, developing 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 operations. Ideally, you possess experience in both manufacturing and development settings, having successfully transitioned multiple products into production while managing their entire product life cycle. A proven history of working with supply chain teams and cultivating relationships with global suppliers and production partners is essential.

This role reports directly to the Plant Operations Manager and is tasked with providing the necessary methodologies and processes to empower the production team in achieving excellence in Quality, Execution, Cost, Flexibility, and Innovation in Methods and Processes.

Key Responsibilities

Safety Management

  • Promote adherence to safety protocols throughout the operation to safeguard yourself and others from potential injuries.
  • Ensure that all manufacturing equipment (including jigs, fixtures, material handling tools, etc.) is designed and utilized safely.
  • Assist the Plant Manager in ensuring that common safety practices are consistently followed.

Cost Optimization

  • Utilize Lean methodologies to initiate and lead projects aimed at reducing manufacturing costs by enhancing manufacturability, touch time, Value Stream Mapping, part flow, and packaging, among others. Conduct regular Gemba walks.
  • Collaborate with the supply chain team to identify and qualify alternative sources for cost improvements.
  • Sample labor times for tasks to maintain labor schedules, always seeking opportunities for time reductions.
  • Participate in auditing the Direct Labor competency matrix as a member of the evaluation board.

Design and Implementation

  • Work closely with 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).
  • Develop and supervise the creation of new manufacturing processes, systems, and technologies to enhance Big Belly's capabilities.
  • Coordinate collaborative project builds with Engineering when production equipment is required.

Troubleshooting and Problem Resolution

  • Provide engineering support to production teams in resolving 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 deployed for conveying instructions and recording results.
  • Coordinate requests for engineering changes, evaluating them and 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 (experience in statistical experiment design is preferred).
  • 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 (Arena preferred).
  • Lean-Six Sigma Greenbelt certification utilizing DMAIC principles is a plus.
  • Proficiency in understanding and applying GD&T.