Senior Manufacturing Engineer
About The Position
Trojan Battery Company is seeking a Senior Manufacturing Engineer to join our team in a high-growth, innovation-driven manufacturing environment. This role is responsible for leading process design, automation, and continuous improvement initiatives, with a strong emphasis on PLC-controlled manufacturing systems, equipment reliability, and process capability. The Senior Manufacturing Engineer serves as a technical leader and problem solver, providing direction to cross-functional teams, mentoring junior engineers, and driving capital projects that improve safety, quality, throughput, and cost. This position plays a key role in advancing automation, controls robustness, and data-driven manufacturing performance across the plant. The ideal candidate is hands-on, technically strong, and comfortable working on the manufacturing floor while also leading strategic initiatives and capital investments.
Requirements
- 5–8+ years of experience in manufacturing with automated and PLC-controlled equipment
- Bachelor’s degree in Electrical, Electronic, Mechanical, or Electro-Mechanical Engineering
- Experience in battery manufacturing, preferably lead-acid
- Hands-on experience troubleshooting Allen-Bradley PLC systems
- Strong understanding of industrial automation components
- Capital project management experience
- Strong analytical, financial, and problem-solving skills
- Proficiency in Microsoft Office, AutoCAD, and statistical software
- Excellent technical documentation skills
- Ability to support off-shift troubleshooting as needed
- Occasional travel required
Nice To Haves
- Experience with OEE systems, MES integration, or PLC data extraction
- Exposure to industrial networking (EtherNet/IP)
- Six Sigma Green or Black Belt
Responsibilities
- Lead the identification, definition, and control of critical process parameters including machine logic, interlocks, alarms, and safety systems
- Troubleshoot complex quality, scrap, throughput, and downtime issues using structured problem-solving methods (A3, 5-Why, Fishbone, DOE)
- Improve process capability through statistical analysis and control of key variables
- Apply Lean Manufacturing principles (Takt Time, SMED, Poka-Yoke, Kanban, Kaizen, 6S, TPM)
- Establish and maintain safe, ergonomic, and compliant manufacturing processes
- Provide senior-level troubleshooting support for Allen-Bradley PLC-controlled equipment (ControlLogix / CompactLogix)
- Diagnose PLC logic, I/O, sensors, VFDs, servos, interlocks, alarms, and fault conditions
- Collaborate with Maintenance, Controls Engineers, and OEMs to resolve recurring automation issues
- Support HMI diagnostics, alarm rationalization, and operator interface improvements
- Participate in PLC change reviews, FAT/SAT activities, and documentation updates
- Utilize PLC data to improve OEE, availability, and downtime reduction
- Lead improvements in corrective, preventive, and predictive maintenance strategies
- Define automation and equipment standards for new capital equipment
- Lead vendor and system integrator technical evaluations
- Own assigned capital project budgets, schedules, and execution from concept through startup
- Ensure projects are delivered safely, on time, and on budget
- Prepare and maintain engineering documentation including Process Flow Diagrams, pFMEAs, Control Plans, SOPs, Job Element Sheets, time studies, capacity analysis, and capital requests
- Ensure compliance with ISO-9001, machine safety standards, and regulatory requirements
- Mentor Manufacturing Engineers and technicians
- Partner with Operations, Quality, EHS, Maintenance, and Supply Chain teams
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What This Job Offers
Job Type
Full-time
Career Level
Mid Level
