Advanced Manufacturing Engineer

Creative Foam Corporation•Fenton, MI

About The Position

The Advanced Manufacturing Engineer leads the development and implementation of manufacturing processes, capital equipment, automation, tooling interfaces, and production systems for thermoformed, polyurethane (PUR), foam-molded, and assembled products. The role works across operations, quality, product development, tooling, maintenance, and external suppliers to industrialize new products and improve safety, quality, delivery, and cost. The position translates product and business requirements into production-ready manufacturing solutions. Its scope includes process concept development, equipment specification and sourcing, line layout, supplier management, installation, commissioning, validation, launch, and continuous improvement. The role has no direct reports but provides technical leadership to cross-functional teams and directs the work of equipment suppliers, automation integrators, contractors, and other project resources. Regular travel of approximately 40–60% is expected to support company plants, equipment suppliers, integrators, and customer locations. Reasonable accommodations may be provided to enable individuals with disabilities to perform the essential functions.

Requirements

Bachelor’s degree in Mechatronics Engineering, Electrical Engineering, Automation Engineering, Mechanical Engineering, or Manufacturing Engineering.
At least three years of experience in manufacturing engineering, advanced manufacturing, process engineering, automation engineering, equipment engineering, or new product launch.
Independently led capital-equipment or production-line projects from concept and specification through installation, validation, and production launch.
Demonstrated ability to develop manufacturing processes and production systems from concept through validated launch and stable production.
Experience specifying, sourcing, installing, commissioning, validating, and improving capital equipment and automated manufacturing systems.
Clear written and verbal communication skills, including the ability to present technical information to plant teams, leadership, customers, machine builders, integrators, and suppliers.
Ability to work independently, manage concurrent priorities, and lead cross-functional teams.
Working knowledge of Lean Manufacturing, Six Sigma, DOE, root-cause analysis, process capability, capacity analysis, and OEE.
Ability to interpret product drawings, tooling designs, machine layouts, mechanical drawings, electrical schematics, fluid-power diagrams, technical specifications, and supplier proposals.
Ability to develop capacity models, cycle-time analyses, equipment acceptance criteria, capital justifications, budgets, schedules, and technical reports.
Strong project management, supplier management, organizational, and technical leadership skills.
Proficiency with Microsoft Office applications, particularly Excel, and working knowledge of AutoCAD, SolidWorks, NX, or comparable CAD/layout tools.
Ability to travel approximately 40–60% to company plants, equipment suppliers, integrators, and customer locations.

Nice To Haves

Experience with thermoforming or vacuum forming equipment, trim systems, tool qualification, and thick-gauge thermoplastic processing.
Experience with polyurethane (PUR), flexible or rigid foam molding, metering and dispensing systems, mold temperature control, and related process equipment.
Experience with robotics, machine vision, PLC-controlled automation, safety systems, material handling, and equipment integration.
Experience in automotive interiors, headliners, trim systems, NVH foam products, composites, plastics, or other high-volume manufacturing operations.

Responsibilities

Develop manufacturing concepts, process flows, equipment requirements, labor plans, capacity models, material-flow strategies, and line layouts for new products and programs.
Support tooling Design for Manufacturability (DFM) reviews as the secondary manufacturing and industrialization representative, providing input on process requirements, equipment integration, production readiness, quality, capacity, and operational risk.
Support plant planning and execution of process trials, pilot builds, capability studies, run-at-rate activities, equipment validation, production-readiness reviews, and production launches.
Specify, source, justify, and implement capital equipment, automation systems, tooling-related equipment, and supporting utilities.
Develop equipment RFQs and SOWs defining technical requirements, scope, deliverables, responsibilities, timing, acceptance criteria, and change-control requirements.
Evaluate supplier proposals, prepare capital justifications and return-on-investment analyses, and manage machine builders, automation integrators, contractors, and equipment suppliers to approved scope, budget, and timing.
Lead design reviews, factory and site acceptance testing (FAT/SAT), installation, commissioning, operator and maintenance training, run-off, and final equipment acceptance.
Provide technical leadership for thermoforming and vacuum forming, PUR metering and dispensing, flexible and rigid foam molding, trimming, routing, bonding, robotic handling, vision inspection, and material handling systems.
Define controls and automation requirements for PLCs, HMIs, robotics, servo systems, machine vision, sensors, safety systems, industrial networks, and equipment interfaces.
Partner with maintenance, operations, and suppliers to resolve equipment, tooling, controls, utility, material, and process-performance issues.
Establish and verify process windows, cycle times, capacity, quality controls, equipment performance targets, and OEE requirements.
Provide hands-on engineering support during equipment launch, production ramp-up, process changes, and resolution of complex manufacturing issues.
Monitor process capability and equipment performance; lead structured root-cause analysis and corrective actions for safety, quality, scrap, downtime, and throughput concerns.
Improve OEE, throughput, labor efficiency, process capability, material utilization, ergonomics, and total manufacturing cost.
Develop and maintain PFMEAs, control plans, process specifications, standard work, equipment documentation, spare-parts requirements, and preventive-maintenance inputs.
Support APQP, PPAP, VDA, ISO, IATF, customer, and internal audit requirements applicable to assigned processes and launches.
Complete or coordinate machine safety risk assessments and ensure equipment and processes comply with company safety requirements, applicable standards, and operational procedures.
Manage concurrent priorities and lead cross-functional teams and project resources.