Sr Manufacturing Engineer (Second Shift)

Eaton Corporation•Arecibo, PR

3d•Onsite

About The Position

The OPEX Senior Engineer provides leadership and technical support to the Arecibo manufacturing operations, including Feeders, Assembly, and Testing areas. This role is responsible for establishing and optimizing manufacturing and testing processes through capacity analysis, process control, cost studies, safety assessments, quality system implementation, equipment maintenance support, and continuous improvement initiatives. Leads and executes projects focused on improving qualification and manufacturing processes, increasing capacity, enhancing productivity and On-Time Performance (OTP), reducing scrap, defects, PPMs, and warranty claims, while improving safety, quality, and operational efficiency. Defines, coordinates, and drives process improvement initiatives to optimize key plant performance indicators, including PPM, Warranty Claims, Fill Rate, On-Time Performance, OEE, Productivity, Yield, and Scrap. Through the application of Lean, Six Sigma, and operational excellence principles, this position supports sustainable growth, cost reduction, customer satisfaction, and overall business performance.

Requirements

Bachelor’s degree in industrial, Mechanical or Electrical Engineering
Minmimum 3 years of experience in manufacturing environment, Lean tools, capacity analysis, manning process, cost savings and capital projects.
Strong background & knowledge in Feeders Metal Forming processes for mechanical and electrical components.
Strong leadership skills
Prioritizes, considers alternatives, and responds quickly and effectively to unexpected and rapidly changing conditions.
Developing, evaluating and improving manufacturing methods and processes to reduce scrap, reduce warranty PPMs and improve OTP.
Analyzing and planning work force utilization.
Development and implementation of manufacturing instructions.
Layout design and modification.
Manufacturing processes continues improvements.
Preparation for Capacity Studies
Perform data analysis and prepare reports
Experience Leading cost savings initiatives and projects.
Experience justifying, managing and implementing capital projects.
Experience using and implementing Lean (Standard Work Flow, Manning, Layout, Operation Balance Chart, VSM and Cross Training).
Provide guidance for the proper selection of manufacturing equipment and tools.
Identification and selection of new technology to improve quality and performance.
PC Proficiency including knowledge of MS windows operating systems, MS Office and Minitab.
EHS practices, regulations, and procedures experience.
Experience supporting internal/external audits including certification renewal.
Proactive attitude towards problem solving and resolving issues that may affect plant/employee’s health, safety, and operations.
Availability to work extended hours when required.
Ability to work under pressure.
Bilingual – English\Spanish with good oral and written communication skills.

Nice To Haves

Equipment malfunctioning impacting production schedules.
Troubleshoots unusual problems to determine root cause (test equipment and/or breakers).
Projects delays due to external vendors issues.
External vendors contractors (Manufacturing equipment supplier)
Equipment, tools and parts suppliers.
Corporate Design Engineering Group (Tech Center).

Responsibilities

Develop, evaluate, and continuously improve manufacturing and testing methods, processes, and systems to enhance safety, quality, productivity, and operational efficiency.
Design, implement, and sustain visual management systems, error-proofing solutions, and embedded testing methods to ensure process control and product quality.
Analyze and optimize workforce utilization, capacity, space requirements, material flow, and work processes to maximize operational performance.
Design and improve equipment layouts, production cells, and workstations to support efficient workflow, ergonomic standards, and Lean manufacturing principles.
Create, review, and maintain Job Safety Analyses (JSAs), Standard Work Instructions (SWIs), Manufacturing Instruction Letters (MILs), visual aids, and other process documentation.
Train, certify, and support manufacturing personnel to ensure compliance with standardized processes, quality requirements, and safety standards.
Develop, update, and deploy Value Stream Maps (VSM) for current and future-state processes to identify improvement opportunities and drive operational excellence.
Provide technical guidance for the selection, specification, procurement, and implementation of manufacturing and testing equipment, tooling, and automation solutions.
Perform capacity analyses and resource planning studies to support demand requirements, production growth, and strategic operational objectives.
Ensure compliance with Lean Manufacturing, Eaton Quality System (EQS), and MESH requirements, including Standard Work, Workflow Design, Manning, Line Balancing, Layout Optimization, Cross-Training, TPM, and Continuous Improvement methodologies.
Lead and facilitate Lean, Kaizen, and Continuous Improvement events to improve productivity, quality, safety, delivery performance, and cost competitiveness.
Support the design, installation, qualification, validation, and continuous improvement of manufacturing and testing equipment.
Monitor manufacturing and testing process performance through data analysis, identify gaps, and implement corrective and preventive actions to resolve issues and sustain improvements.
Collect, analyze, interpret, and present operational data and performance metrics to support decision-making and drive business results.
Apply Lean Six Sigma tools and statistical methodologies, including Measurement System Analysis (MSA), process capability studies, and root cause analysis, to improve process performance and reduce variation.
Identify, develop, and execute cost reduction and productivity improvement initiatives to achieve annual business objectives and savings targets.
Justify, manage, and execute capital investment projects, including appropriation requests, requirement definition, vendor selection, quotation review, procurement, project tracking, reporting, and implementation.
Conduct safety assessments, risk evaluations, and remediation projects in coordination with the MESH organization to ensure compliance and reduce workplace hazards.
Promote and reinforce all MESH policies, procedures, and safety initiatives, ensuring adherence throughout assigned areas of responsibility.
Participate in Environmental, Health, and Safety (EHS) investigations, including incident analysis, root cause determination, and implementation of corrective actions.
Evaluate, recommend, and implement new technologies, automation solutions, and advanced manufacturing techniques to improve quality, efficiency, capacity, and safety.
Develop, maintain, and validate Job Safety Analyses (JSAs) and risk mitigation plans for manufacturing and testing operations.
Lead and respond to Customer Quality Metrics (CQMs), CAPAs, nonconformances, and corrective action requests by implementing containment actions, conducting root cause analyses, and ensuring timely closure of action plans.
Support and participate in internal and external audits, including ISO, EQS, MESH, Lean, customer, and regulatory audits, ensuring compliance and continuous improvement.
Lead cross-functional projects focused on improving key performance indicators, including PPM, Warranty Claims, Fill Rate, On-Time Performance (OTP), OEE, Productivity, Yield, Scrap, and overall customer satisfaction.
Collaborate with Operations, Quality, Maintenance, Engineering, Supply Chain, and EHS teams to achieve plant objectives and support strategic business initiatives.
Lead Tier 2 performance reviews by monitoring key operational metrics through dashboards, Power BI, PcAT, MES, Ignition, and other digital manufacturing platforms. Drive rapid response actions, assign ownership, and follow up to ensure timely resolution and sustained improvements.
Support the deployment, adoption, and effective utilization of digital manufacturing systems across the plant through Tier 2 dashboards, visual management tools, and shop-floor connectivity solutions.
Provide technical guidance and troubleshooting support for system functionality issues, ensuring minimal disruption to manufacturing operations.
Monitor system utilization, analyze discrepancies, identify performance gaps, and develop corrective and preventive actions to improve data accuracy and process effectiveness.
Support the administration, maintenance, and continuous improvement of PcAT, MES, Ignition, and PDES user interfaces and system functionality.
Ensure compliance with and consistent usage of PcAT, MES, Ignition, PDES, and related digital manufacturing systems throughout production areas.
Communicate system issues, data anomalies, and operational risks during Tier meetings, driving visibility, accountability, and timely resolution.
Provide ongoing support, maintenance, and deployment of manufacturing workstations, including new workstation setup, upgrades, and infrastructure coordination.
Develop and implement Industry 4.0 (I4.0) and Continuous Improvement (CI) initiatives to drive digital transformation, optimize manufacturing processes, increase productivity, improve quality, and support strategic plant objectives.
Develop, maintain, and enhance dashboards and reporting tools to monitor Overall Equipment Effectiveness (OEE), process performance, system utilization, and other key operational metrics, enabling data-driven decision making.
Collaborate with Operations, Quality, PLS Engineering, IT, and Maintenance teams to leverage digital solutions that improve operational excellence, productivity, customer satisfaction, and business performance.