Sr Advanced Manufacturing Engineer - Assembly (Wauwatosa, WI, US)

Job Summary

The Senior Engineer – Advanced Manufacturing (Assembly) plays a key role in the manufacturing process development and implementation and is responsible for supporting and delivering the Life Cycle Plan from concept to production at our various manufacturing plants. This role works collaboratively with Product Development, Quality, Supply Chain, and Plant Operations to yield innovative products and processes. The role requires strong leadership through expertise, decision influence, and cross-functional collaboration. Impacts opportunities to influence design for assembly and solves complex problems with development of integrated manufacturing systems, standardized processes and templates, risk assessment and mitigation, and after-action reviews.

Job Responsibilities

Assembly Engineering, Tooling & Launch Support

• Lead assembly process development and solve complex problems involving medium to large scale projects from concept to development, through capital funding planning and approval, and ultimately through successful implementation using analytical thought, exercising judgment and identifying innovative solutions.
• Influence Design for Assembly (DFA) by engaging early with Product Development and incorporating manufacturing and plant lessons learned.
• Define, design, and implement assembly tooling, fixtures, gauges, and equipment, including capital planning, supplier sourcing, and installation.
• Support make/buy analysis to inform product and process decisions, including evaluation of in-house vs. supplier assembly and tooling solutions with should cost analysis.
• Perform supplier technical assessments and implement supplier technical development plans
• Define, validate, and approve torque strategies, fastening methods, and error-proofing concepts.
• Serve as the technical escalation point for complex assembly, tooling, equipment, and quality issues during builds and start of production.
• Support build events (VB, PB, Pre-Pod) ensuring station readiness, documentation accuracy, and execution.

iPPAP / PPAP, PFMEA & Control Plan Ownership

• Serve as the Advanced Manufacturing lead or core contributor for iPPAP and PPAP readiness for assembly processes.
• Lead or support development and maintenance of PFMEAs and Control Plans for assembly processes, ensuring alignment with plant execution and quality requirements.
• Ensure completeness and accuracy of manufacturing deliverables including process flows, SWS, BOMs, tooling lists, PFMEAs, and Control Plans.
• Lead validation of tooling capability, fixture readiness, equipment capability, torque tool MSA, and capability studies.
• Identify and close manufacturing readiness gaps prior to PB, Pre-Pod, and SOP milestones.
• Support quality audits, launch holds, and post-SOP issues related to new product iPPAP/PPAP compliance and process adherence.

Project Management & Execution

• Apply project management tools and techniques to manage scope, cost, timing, and risk for assembly and tooling deliverables.
• Develop and manage capital budgets, cost estimates, and spend tracking for tooling, equipment, and assembly solutions.
• Maintain detailed project plans and ensure alignment to NPD milestones and plant readiness targets.

Continuous Improvement

• Use Manufacturing principles including CI, Six Sigma, and 5S.
• Drive structured problem solving using 8D and continuous improvement methodologies.
• Ensure production feedback is used to drive ongoing product and process improvements.

Optional / Value-Add Capabilities

• As program needs require, the Senior Engineer may support digital manufacturing activities such as virtual DFA reviews, ergonomic assessments, or virtual builds. Digital manufacturing experience is a value-add, not a prerequisite.

Education Requirements

Education Specifications

Bachelor’s degree in Engineering preferred (Mechanical, Industrial, Manufacturing, or related field).

Experience Requirements

This position typically requires a minimum of 5 years of related experience in manufacturing, assembly engineering, tooling, or launch-related roles.  In addition, the successful candidate will have demonstrated the followin

• Demonstrated experience in New Product Development, launch support, and cross-functional problem solving.
• Experience supporting make/buy analysis, tooling and equipment implementation, and iPPAP / PPAP processes.
• Working knowledge of PFMEA, Control Plans, and manufacturing quality systems.
• Strong analytical, communication, project management, and decision-making skills.
• Demonstrated ability to work effectively within and / or lead a group or team providing guidance to members