Manufacturing Engineer

Thompson Manufacturing Inc. (Rock Exotica)•Clearfield, IA

26d•Onsite

About The Position

The Manufacturing Engineer is responsible for developing, implementing, and sustaining efficient manufacturing processes that ensure Rock Exotica products are produced accurately, safely, and cost-effectively. This role places a strong emphasis on process engineering; including PFMEA, line balancing, lean manufacturing, machine design, and continuous improvement to optimize workflow, reduce waste, and improve production throughput and quality. The Manufacturing Engineer serves as the technical authority for all process design decisions and is the primary R&D liaison to Production for process-related matters.

Requirements

Deep knowledge of process engineering and manufacturing systems, including tooling design, fixturing, and assembly machine development.
Strong knowledge of Lean Manufacturing principles and tools (Kaizen, 5S, SMED, VSM, standard work).
PFMEA development and linkage to control plans and process validation.
Proficiency in line balancing, workstation layout, and process flow optimization.
Data-driven problem solving and root cause analysis.
Project planning and cross-functional collaboration.
Initiative and ability to execute continuous improvement independently.
Clear, concise communication and documentation skills.
Strong sense of ownership, urgency, and follow-through.
Provides technical direction to the Manufacturing Engineering Technician.
Provides technical direction to the Mechanical Engineering Technician when assigned to manufacturing projects by the R&D Manager.
Bachelor's degree in mechanical, Manufacturing, Industrial, or Materials Engineering, or a related field.
3+ years of experience in a manufacturing engineering or process engineering role within a durable goods environment.
Demonstrated experience with PFMEA development, process validation, and capability studies.
Hands-on experience designing production tooling, fixtures, or manufacturing equipment.
Proficiency in SolidWorks or equivalent CAD software.
Experience with lean manufacturing, process improvement, and production line optimization.
Strong organizational skills with ability to prioritize in a fast-paced environment.

Nice To Haves

Experience in a precision machined components or hardware manufacturing environment.
Familiarity with PPAP and FAI processes.
Experience with assembly machine design, FAT, and SAT.
Exposure to ERP systems for routing and work center management.
Passion for technical products — ideally in outdoor, safety, or industrial equipment.

Responsibilities

Designs, develops, and sustains manufacturing processes that produce conforming product accurately, safely, and efficiently.
Owns the Process Failure Mode and Effects Analysis (PFMEA) — develops, maintains, and links to the control plan for all new and revised products and processes.
Conducts process verification activities, including capability studies (Cpk), process validation, and sign-off for production readiness.
Performs root cause analysis and corrective action (RCCA) for process-related issues.
Conducts time and motion studies, capacity analysis, and value stream mapping to identify and eliminate waste.
Participates in the manufacturing launch of new and revised products — leads process readiness activities including process design, tooling development, line qualification, and production team training.
Collaborates with the Development Engineer on production documentation, ERP router development, and work instruction review to ensure process accuracy.
Assists Design Engineers in resolving product manufacturability issues; contributes to Design for Manufacturing (DFM) reviews.
Supports first article inspections (FAI) and PPAP activities for new products and processes.
Collaborates with the Assembly Manager and production teams to improve production control systems, SOPs, safety protocols, and training materials.
Owns the creation, updating, and maintenance of ERP production routing data, ensuring accuracy of work center sequences and process steps.
Performs miscellaneous duties and special projects as assigned.
Designs, develops, qualifies, and continuously improves production process tooling — including assembly fixtures, jigs, and assembly aids — optimized for ergonomics and efficiency.
Owns the design and development of assembly machines and production equipment, including Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT).
Manages tooling capital requests and coordinates tooling purchase orders within R&D, in collaboration with the R&D Manager.
Provides technical direction to the Mechanical Engineering Technician (when assigned) and Manufacturing Engineering Technician on tooling development, build, and qualification.
Leads line balancing studies and implements efficient workstation layouts to support takt time and throughput goals.
Identifies and implements lean manufacturing improvements including 5S, standard work, visual management, and waste elimination (TIMWOOD).
Drives and facilitates continuous improvement (CI) initiatives to reduce cycle time, improve quality, and lower production costs.
Represents Manufacturing Engineering on cross-functional CI events including kaizen, Gemba walks, and A3 problem solving.