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Salary: USD 130,000 - 180,000 / annual
Heron Power is building cutting-edge power electronics to accelerate grid modernization and electrification. As a Senior/Staff Manufacturing Engineer – Advanced Processes, Inspection & Test, you will own the development, testing, deployment, and scaling of manufacturing processes, inline inspection, and electrical test strategies for high-volume transformer assembly lines.
You will lead development of inline inspection, process monitoring, and automated electrical test across the transformer assembly line, from concept through vendor selection, FAT/SAT, commissioning, validation, and production ramp. This includes designing and deploying high-speed automated inspection of potted assemblies using X-ray/CT, ultrasonic, thermography, and machine vision to detect voids, delamination, incomplete fill, and cure defects.
You will architect surface treatment processes such as atmospheric plasma/corona treatment, solvent/chemical cleaning, and adhesion preparation, with inline verification of treatment uniformity and quality. You will also architect and deploy automated high-volume electrical test equipment covering capacitance, inductance, DC resistance, conductivity/resistivity, impulse, AC resistance, hipot, and partial discharge testing, including test sequencing, fixturing, shielding/noise control, and limit setting to balance cycle time, yield, and escape risk.
Collaboration is central to this role. You will partner with manufacturing engineers on high-viscosity potting and dispense systems, high-speed plastic welding processes (ultrasonic, hot plate, IR), and robust inline process monitoring. You will lead MSA, Gage R&R, and test method validation for inspection and electrical test systems, including golden/limit samples and correlation to lab methods. You will apply PFMEA, control plans, SPC methodology, and structured problem solving to maintain world-class process capability, and support automation integration with robots, conveyors, and inline QA.
The role requires working closely with product, mechanical, and electrical design teams early and often through DFM, designing processes from first principles, and closing feedback loops to ensure both product and manufacturing lines are robust. You will collaborate with external suppliers and equipment partners to land scalable, reliable, and highly repeatable equipment lines and processes.
REQUIREMENTS:
- Bachelor's degree in Manufacturing, Industrial, Mechanical, Electrical, or Chemical Engineering
- 7+ years of experience in high-volume manufacturing with focus on process engineering, inline inspection, production test, or automation for electromechanical, power electronics, magnetics, or battery products
- Hands-on experience deploying automated non-destructive inspection (X-ray/CT, ultrasonic, thermography, or vision) to detect voids, delamination, or bond-line defects in production
- Experience developing and validating automated electrical test for high-volume production
- Experience with design, optimization, and validation for high-viscosity potting and dispense systems including material supply, metering, mixing, vacuum potting, and degassing strategies
- Experience with surface preparation processes and quantitative surface quality measurement
- Experience with ultrasonic, hot plate, and/or IR welding of plastics, including process monitoring and weld validation
- Proficiency in statistical analysis, SPC, Cp/Cpk studies, hypothesis testing, and Minitab/JMP
- Demonstrated ability to run DoEs and optimize complex processes
- Experience implementing PFMEAs, control plans, and process flow diagrams
- Hands-on experience with automation, robotics, PLCs, and vision systems
NICE TO HAVE:
- Experience with injection molding processes and tooling
