Production Engineer- Active Parts Assembly

Delta Star • Lynchburg, VA

8d

About The Position

Delta Star Inc. is seeking a motivated and process‑driven Production Engineer, Active Parts Assembly to support continuous improvement efforts across manufacturing operations. If you excel at optimizing processes, partnering with production teams, implementing new equipment, and driving Lean initiatives, we want to hear from you! As a member of the Operational Excellence team, you will evaluate and improve production processes, deploy new tools and equipment, and act as the key liaison between product design engineering and manufacturing. You’ll champion Lean manufacturing, develop standard work, and help ensure that new solutions are efficient, safe, and manufacturable. Your day may include walking the production floor to identify improvement opportunities, performing time studies, troubleshooting manufacturing challenges, or leading a Kaizen event. You’ll develop work instructions, implement 5S standards, assist with capital equipment deployments, and collaborate with engineering and production teams to ensure efficient transformer manufacturing. You’ll also create training materials, deliver presentations, and report on project progress, KPIs, and ROI.

Requirements

• Electrical Engineering degree (EE).
• Demonstrated understanding of transformer active‑part electrical design (windings, insulation structure, electrical connections).
• Minimum 5 years of experience in transformer manufacturing (winding, active‑part assembly, and/or final assembly).
• Experience as a supervisor, team leader, or improvement project lead.
• Lean Manufacturing or Six Sigma Green Belt certification (or ability to obtain).
• Ability to Define, Measure, Analyze, Implement, and Control improvements (DMAIC).
• Strong prioritization and root‑cause analysis skills.
• Solid understanding of electro-mechanical assembly, machining processes, and transformer operations.
• Ability to communicate clearly with all levels of the organization, as well as with suppliers and customers.
• Knowledge of Lean manufacturing techniques and ability to create standard work.
• Excellent communication, teamwork, and interpersonal skills.
• Strong analytical mindset with initiative and continuous‑improvement focus.

Responsibilities

• Evaluate existing and new processes to enhance safety, quality, and efficiency.
• Prepare or update manufacturing operating procedures, work instructions, and SOPs for high‑voltage transformer production.
• Select, deploy, and support proper tools and equipment for manufacturing.
• Lead and participate in manufacturing improvement projects, including defining objectives, action plans, and KPIs.
• Maintain and update 5S standards for active‑part assembly areas.
• Support capital equipment implementation, including evaluation, selection, run‑offs, and installation.
• Conduct time studies (process times and cycle times) to meet takt time expectations.
• Troubleshoot manufacturing issues using electrical and mechanical knowledge of transformer builds.
• Ensure adherence to quality and efficiency standards across production areas.
• Create training materials and deliver presentations to manufacturing and administrative audiences (including transformer basics and CTQ elements).
• Provide recommendations on machinability, assembly, processing standards, and ROI for improvement initiatives.
• Report on project progress to management.
• Collaborate with U.S. and Canadian sites to collect data and support cross‑factory initiatives.
• Perform other duties as assigned.

Benefits

• comprehensive benefits package to support you and your family, including medical, dental, vision, life, and disability coverage
• retirement offerings vary by location but include employer contributions to retirement plans, an Employee Stock Ownership Plan (ESOP), and a corporate bonus plan
• paid time off, sick pay, floating holidays, and access to programs such as flexible spending accounts or similar consumer benefits
• education assistance

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level
• Number of Employees: 251-500 employees