Senior Launch Engineer

Position Summary

The Senior Launch Engineer is responsible for leading the successful introduction of new products, processes, equipment, and engineering changes into the Blacksburg manufacturing operation. This position serves as a key technical and project leadership resource, driving launch activities from initial planning through production readiness, validation, and stabilization.

The Senior Launch Engineer works closely with Manufacturing, Quality, Maintenance, Supply Chain, Operations, suppliers, customers, and corporate engineering teams to ensure launch objectives are achieved safely, on time, within budget, and in accordance with customer and quality requirements.

Key Responsibilities

• Lead new product and manufacturing process launches from concept through production readiness and stabilization.
• Develop and manage comprehensive launch plans, including timing, milestones, resources, deliverables, risks, and escalation requirements.
• Serve as the primary engineering lead for assigned launch programs and provide technical direction throughout the launch process.
• Coordinate activities across Engineering, Operations, Manufacturing, Quality, Maintenance, Supply Chain, and other key functions.
• Lead prototype builds, pre-production trials, equipment runoffs, process validations, and production readiness activities.
• Drive APQP deliverables and support PPAP requirements, PFMEAs, Control Plans, process flows, work instructions, and related launch documentation.
• Identify launch risks early and develop effective mitigation and contingency plans.
• Lead technical problem-solving and root cause analysis for equipment, process, quality, capacity, and manufacturing issues.
• Coordinate the implementation of Engineering Change Notices (ECNs) and ensure changes are properly validated before production implementation.
• Participate in design reviews and provide Design for Manufacturability feedback to product and design engineering teams.
• Support installation, commissioning, qualification, and ramp-up of new manufacturing equipment and processes.
• Monitor manufacturing performance during launch, including quality, scrap, cycle time, throughput, downtime, and process capability.
• Track launch milestones, open issues, corrective actions, and readiness status and communicate risks to plant and corporate leadership.
• Support customer technical requirements and resolution of launch-related quality or manufacturing concerns.
• Coordinate with suppliers and equipment vendors when technical support or corrective action is required.
• Identify opportunities to improve manufacturing efficiency, process capability, quality, cost, and overall launch performance.
• Provide technical guidance and mentoring to engineers and other launch team members, as appropriate.

Required Qualifications

• Bachelors degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, or a related engineering discipline.
• Five or more years of progressive engineering experience, preferably within automotive or high-volume manufacturing.
• Demonstrated experience leading new product, equipment, or manufacturing process launches.
• Strong working knowledge of APQP, PPAP, PFMEA, Control Plans, root cause analysis, and structured problem-solving.
• Strong project management skills with the ability to manage multiple priorities, deadlines, risks, and cross-functional deliverables.
• Demonstrated ability to troubleshoot manufacturing processes and resolve complex technical issues.
• Strong written and verbal communication skills with the ability to communicate effectively with shop-floor employees, engineers, suppliers, customers, and leadership.
• Proficiency with Microsoft Office and applicable engineering and manufacturing systems.

Preferred Qualifications

• Experience within the automotive manufacturing industry.
• Working knowledge of IATF 16949 and ISO 14001 environments.
• Six Sigma Green Belt or similar continuous improvement certification.
• Experience with Lean Manufacturing principles and structured continuous improvement.
• Experience launching new manufacturing lines, automated equipment, tooling, or significant process changes.
• Experience working in a unionized manufacturing environment.
• Familiarity with CAD and ERP/MES systems applicable to manufacturing operations.

Key Competencies

• Technical leadership and sound engineering judgment
• Project and launch management
• Manufacturing problem-solving
• Cross-functional leadership and collaboration
• Risk identification and mitigation
• Results orientation and accountability
• Customer focus
• Continuous improvement
• Clear communication
• Ability to work effectively in a fast-paced manufacturing environment

Working Conditions

• Primarily an on-site position within a manufacturing environment.
• Requires regular interaction with production operations and manufacturing equipment.
• May require flexibility to support critical launch activities outside normal business hours.
• Occasional travel to suppliers, customers, or other company facilities may be required.