Manufacturing Engineer (NPI)
On-sitePittsburgh, Pennsylvania, United States
Job Summary
Drive APQP Program Management at CM/Tier 1 sites, ensuring flawless Start of Production (SOP) and obtaining PPAP deliverables. Design for Manufacturing (DFM) & Assembly (DFA) to provide design maturity feedback, validating component-level PPAPs and integrating them into the assembly process. Lead the development of Process PPAP deliverables including PFMEAs, Control Plans, and Work Instructions to mitigate assembly risks with "Poka-Yoke" solutions. Design and qualify manufacturing equipment, tooling, and gauges, ensuring process controls meet GD&T and tolerance requirements through MSA and Gage R&R. Support Process Verification (PV) Testing with "Run-at-Rate" studies to prove line sustainability at full speed. Lead internal and CM-based RCCA using the 8D methodology to resolve technical assembly failures. Collaborate with Field Quality teams to update Control Plans based on real-world performance data from OEM partners.
Required Qualifications
- Bachelors of Science in Mechanical Engineering or similar fields
- NPI & CM Oversight Experience: Proven track record of launching automotive or high-tech hardware at Tier 1 or Contract Manufacturers using structured quality gates
- Technical ownership of the launch cycle, specifically focusing on the transition from prototype to a production-validated manufacturing line
- Advanced APQP & PPAP Management: Mastery of Control Plans, Process Flows, and Gage R&R, with a specific focus on manufacturing process stability (Cpk). Experience managing the transition from Design Verification (DV) to Process Verification (PV) and overseeing full PPAP submissions for complex electromechanical systems
- Proficient with Solidworks for reviewing assembly fixtures, pallets, and inspection jigs
- Expertise in GD&T & Metrology: Deep understanding of how to verify complex mechanical tolerances in a production environment using CMM, OMM, or vision systems
- Problem-Solving Expert: Mastery of 8D and RCCA, with the ability to lead high-pressure technical resolution activities during a production ramp
- Experience with PLM tools and document revision control to manage Engineering Change Orders (ECOs) and ensure BOM accuracy during the APQP cycle
- Experience with various manufacturing processes such as precision torque, thermal interface material (TIM) dispensing, and high-stakes sensor calibration
- Present manufacturing readiness to cross-functional teams, using data-driven insights to justify the move from APQP Phase 3 to Phase 4
Desired Qualifications
- Automotive, Aerospace, Autonomous Vehicle (AV) or EV industry experience is highly preferred
- IPC/WHMA-A-620 and IPC-A-610 knowledge for acceptance of wire harness assemblies and electronic assemblies
- Experience with Robotic Workcells or automated assembly systems
- Certified Quality Engineer (CQE) or Six Sigma Green/Black Belt
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