Senior Manufacturing Engineer

Alloy Surfaces Co Inc•Chester Township, PA

29d•Onsite

About The Position

The Senior Manufacturing Engineer for Alloy Surfaces Company (ASC) establishes, monitors, and improves processes related to the manufacture of complex commercial, defense, and aerospace products and systems. This position operates with minimal supervision and provides technical leadership for manufacturing process development, tooling and equipment, production readiness, and continuous improvement. The Senior Manufacturing Engineer develops and maintains manufacturing processes that produce products at the lowest practical cost, at quality levels exceeding customer expectations, and on or ahead of schedule.

Requirements

Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, Materials Science, Manufacturing Engineering or related field
Minimum of six years of experience in a regulated manufacturing environment, preferably aerospace or defense
Experience in the application of Design for Manufacturing and Assembly (DFMA) and Design for Cost (DFC) principles
Must be eligible to obtain and/or maintain a U.S. Government Security Clearance commensurate with the level of facility clearance
Strong interpersonal, communication, influencing, and organizational skills with the ability to collaborate effectively across all levels of the organization
Excellent problem-solving skills with the ability to apply sound judgment, initiative, and creativity to complex technical challenges
Strong capabilities and experience supporting manufacturing production lines, e.g., resolving line-down events, troubleshooting, and creating standard operating procedures and work instructions
Ability to develop reports, business correspondence, technical documentation, and quality procedures
Ability to manage competing priorities in a fast-paced manufacturing environment
Statistical Analysis and Statistical Process Control
Fault proofing, Root Cause Analysis
Process Mapping /Value Stream Mapping
Understanding of AS9100 and/or ISO 9001, and Lean Six Sigma Techniques
Manufacturing process development and planning, test plan development
Control and disposition of non-conforming material
Working knowledge of CAD (Creo, SolidWorks, etc.) and Manufacturing ERP systems
Proficiency with Microsoft Office Suite

Nice To Haves

Lean Six Sigma Green Belt certification preferred
Experience in Design for Manufacturability Analysis preferred

Responsibilities

Lead the evaluation, development, qualification, and implementation of new technologies, processes, equipment, tooling, and fixtures, and share lessons learned and best practices
Perform and facilitate ergonomic assessments, Process Hazard Analyses (PHA), and Job Hazard Analyses (JHA) to ensure manufacturing processes incorporate appropriate safety controls
Develop manufacturing documentation including instructions, routers, bills of material, assembly procedures, build sequences, and rework/repair instructions
Collaborate with Engineering, suppliers, and subject matter experts during product design and reviews to provide DFM, producibility, materials, tooling, and manufacturing process recommendations
Troubleshoot manufacturing and product quality issues using root cause and failure analysis; lead corrective actions and provide technical support to resolve significant or line-down issues
Support the disposition of non-conforming material and develop rework, repair, and corrective action requirements for internal and supplier-related issues
Lead and participate in continuous improvement initiatives using Lean, Six Sigma, Kaizen, 5S, Kanban, QCO, and other methods to improve efficiency, quality, cost, and process capability
Lead assigned manufacturing engineering and CapEx projects including project planning, scheduling, budgeting, resource management, design oversight, and vendor coordination
Collaborate with management, Engineering, Production, Quality, customers, suppliers, and other stakeholders to communicate technical issues, manufacturing strategies, root cause findings, and performance metrics
Assist in the development of transition to production plan(s) and determine full-rate tooling and equipment needs
Provide input to activities such as supplier evaluation, source selection, request for proposal submittal reviews, best value determination, and supplier capacity analysis
Attend activities including Supplier Production Readiness Evaluation (SPRE) and Manufacturing Product Process Verification (MPPV) events
Provide technical expertise in analyzing and improving supplier manufacturing capabilities, capacity, manufacturing, test, failure analysis, and part selection
Review drawing changes and contract modifications to determine impact to the manufacturing process and incorporate the required changes
Contribute to new business proposal activity in cost estimating and developing manufacturing strategy
Define and improve the product value stream and process capabilities for different types of manufacturing processes and equipment
Apply knowledge of product design, materials, and production processes to define assembly procedures and build sequences to drive operational efficiency
Define materials, tooling, fixtures, and manufacturing methods to ensure safety and quality are incorporated into the process design
Influence the development of manufacturing strategy for the area of responsibility including work cell layouts, equipment, tooling, and processes/systems
Ensure compliance with all company policies and procedures, including but not limited to the Code of Conduct, U.S. Code of Ethics and Business Conduct, and the Chemring Operational Framework
Ensure the Group ethos of all employees going home safely at the end of their working day is adhered to
Promote a high standard of ethical behavior and adherence to the Group’s core values, and promote a culture of honesty and integrity across ASC
Comply with government and corporate laws, rules, regulations, policies, and procedures
Special projects and additional duties as assigned