Senior Manager Manufacturing & Industrial Engineering

PowerSecure, Inc.•Durham, NC

14h•Hybrid

About The Position

The Senior Manager, Manufacturing & Industrial Engineering leads the Manufacturing Engineering and Industrial Engineering functions, converting product engineering intent into safe, repeatable, production-ready manufacturing systems. The role owns the processes for translating engineering bills of material (eBOMs) into manufacturing bills of material (mBOMs), routings, manufacturing methods, tooling requirements, standard work, and work instructions. It also leads plant and value-stream layout development, capacity modeling, manufacturing simulation, equipment requirements and capacity analysis, labor and workstation planning, and production-system design for new and expanding operations. The position partners with Product Engineering, Operations, Quality, Supply Chain, Material Flow, Maintenance, Facilities, Strategic Capital Projects, Safety, and Continuous Improvement. Manufacturing & Industrial Engineering designs, industrializes, launches, and technically governs the manufacturing system. Continuous Improvement owns structured improvement within established plants after processes transition to sustained operations. This hybrid position may require occasional travel for training or meetings. The employee must be able to work flexible hours to accommodate different time zones when necessary and be flexible for after-hours tasks as needed.

Requirements

Bachelor's degree in Manufacturing Engineering, Industrial Engineering, Mechanical Engineering, or a related engineering discipline.
At least 6 years of progressive experience in manufacturing engineering, industrial engineering, manufacturing operations, or a related technical field, including leadership of engineering teams.
Demonstrated experience translating product designs and eBOMs into mBOMs, routings, manufacturing methods, standard work, and production documentation.
Strong experience with plant layout, value-stream design, capacity analysis, equipment planning, production flow, labor modeling, workstation design, and line balancing.
Experience using manufacturing simulation, analytical modeling, or digital engineering tools to evaluate production scenarios, constraints, equipment utilization, staffing, and facility requirements.
Experience supporting new product introduction, facility expansion, new production lines, major equipment installations, or greenfield manufacturing launches.
Working knowledge of Design for Manufacturability, Design for Assembly, ergonomics, process capability, production readiness, and manufacturing change control.
Strong leadership, communication, project management, problem-solving, and cross-functional decision-making skills.
Ability to establish common engineering standards across multiple plants while maintaining clear accountability for execution at the site and value-stream levels.
Ability to work flexible hours across Central, Eastern, Mountain, and Pacific time zones when necessary, and to be flexible for after-hours tasks as needed.

Nice To Haves

Master's degree.
Experience in complex, high-mix, engineered-to-order, or configure-to-order manufacturing environments.

Responsibilities

Lead, develop, and align the Manufacturing Engineering and Industrial Engineering teams across the manufacturing organization.
Establish common engineering standards, methods, governance, tools, and deliverables for manufacturing system design and product industrialization.
Develop the engineering roadmap to support volume growth, product complexity, additional shifts, facility expansion, and new plant launches.
Define decision rights, technical ownership, and handoffs among Product Engineering, Manufacturing Engineering, Industrial Engineering, Operations, Continuous Improvement, and supporting functions.
Build a scalable engineering capability that creates reusable standards and reduces plant-specific or one-off manufacturing solutions.
Own the process for translating engineering designs and eBOMs into accurate mBOMs, routings, operations, work centers, and executable manufacturing processes.
Define manufacturing methods, process sequences, standard work, work instructions, tooling, fixtures, gauges, and production documentation required for release to manufacturing.
Lead Design for Manufacturability and Design for Assembly reviews with Product Engineering and ensure manufacturing requirements are considered early in product development.
Establish manufacturing readiness criteria and lead industrialization for new products, engineering changes, and product transfers.
Validate technical manufacturing standards, process controls, tooling requirements, and documentation before transition to sustained production.
Provide technical engineering support for production issues requiring changes to manufacturing methods, tooling, fixtures, equipment, or process design.
Develop current-state and future-state plant, department, value-stream, production-line, and workstation layouts.
Create capacity models across equipment, processes, labor, work centers, utilities, and facilities to support operating plans and long-range growth decisions.
Develop manufacturing simulations and scenario analyses to evaluate production strategies, volume changes, staffing, equipment investments, space constraints, and alternative flow concepts.
Determine equipment requirements, quantities, technical capabilities, utilization targets, and required capacities based on demand, product mix, process requirements, and manufacturing strategy.
Identify manufacturing constraints and recommend engineered solutions involving layout, equipment, automation, labor, sequencing, or process redesign.
Lead workstation design, labor planning, ergonomic considerations, launch-stage line balancing, and production-system validation.
Partner with Supply Chain and Material Flow Engineering to ensure layouts support receiving, storage, supermarkets, point-of-use presentation, replenishment, WIP control, and internal logistics.
Provide manufacturing and industrial engineering leadership for new facilities, facility expansions, new production lines, and major manufacturing transformations.
Translate demand forecasts and product strategy into space, equipment, labor, infrastructure, and capital requirements.
Develop conceptual manufacturing layouts, process concepts, equipment strategies, capacity assumptions, and technical scopes for capital projects.
Partner with Strategic Capital Projects, Facilities, Operations, Safety, Maintenance, Quality, and Supply Chain during design, selection, installation, commissioning, and production ramp-up.
Establish and validate manufacturing readiness, capacity, and technical acceptance criteria before releasing new equipment, lines, or facilities into sustained production.
Design manufacturing systems using Lean principles while recognizing Continuous Improvement's ownership of structured improvement within established plants.
Establish a transition from engineering-led industrialization, launch, and stabilization to Operations ownership and Continuous Improvement support after processes reach sustained production.
Partner with Continuous Improvement when established operations require engineering analysis, simulation, time studies, capacity modeling, equipment changes, layout redesign, automation, or fundamental changes to manufacturing methods.
Incorporate Operations and Continuous Improvement lessons learned into future product industrialization, plant designs, equipment specifications, manufacturing standards, and launch processes.
Evaluate successful plant improvements for standardization and deployment in future facilities, production lines, and product introductions.
Recruit, coach, and develop manufacturing and industrial engineering talent; establish performance expectations and succession plans.
Establish measurable engineering deliverables for manufacturing readiness, documentation accuracy, capacity validation, equipment performance, launch execution, and standardization.
Manage departmental priorities, resources, budgets, and project commitments in alignment with manufacturing strategy and business needs.
Communicate risks, assumptions, capacity constraints, capital needs, and recommended decisions to senior leadership clearly and factually.