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Mainspring Energy manufactures fuel-flexible, low-emissions local power solutions for Fortune 500 companies, data centers, and utilities. They seek a Staff Manufacturing Process Engineer to bridge product development and scalable manufacturing.
You will partner with Mechanical, Electrical, Manufacturing, Quality, and Supply Chain teams to develop robust, scalable manufacturing processes enabling safe, repeatable, high-volume production. This is a strategic role—not downstream execution. You will proactively influence product and process decisions by leveraging shop floor data, structured experimentation, and production lessons learned to eliminate manufacturing risks before they impact volume.
Key responsibilities include:
**Manufacturing Process Development**: Develop, validate, and optimize processes from prototype through high-volume production. Lead process validation using PFMEA, DOE, capability studies, and GR&R. Drive cross-functional risk mitigation with Design, Quality, and Operations. Establish manufacturing readiness plans and quality gates for new product introductions.
**Manufacturing Optimization & Operational Excellence**: Partner with Industrial Engineering on cycle times, line balancing, and resource utilization. Drive touch-time reduction through process optimization, assembly sequencing, ergonomic improvements, and automation. Lead root cause investigations using 8D, 5 Whys, DOE, and statistical analysis to improve first-pass yield and process capability. Identify and eliminate bottlenecks to improve throughput, labor productivity, and OEE. Champion Lean Manufacturing, error-proofing, standardization, and continuous improvement.
**Manufacturing Scale-Up**: Own the transition from prototype to scalable production systems. Partner with Quality, Supply Chain, Operations, and NPI teams on new process launches. Support factory layout, line design, capacity planning, and equipment selection. Lead new factory launches, manufacturing transfers, and production ramps across domestic and international sites.
Required qualifications: 10–15+ years of manufacturing/process engineering experience with complex electromechanical products. Expertise in PFMEA, Control Plans, Process Flow Diagrams, DOE, SPC, 8D, Cpk, and GR&R. Experience developing scalable processes and supporting NPI from prototype through high-volume production. Strong knowledge of Lean Manufacturing, Six Sigma, Kaizen, line balancing, Yamazumi charts, time studies, and capacity modeling. Proven ability to lead cross-functional initiatives and influence decisions through data. Experience in automotive, aerospace, energy, or high-volume electromechanical manufacturing.
Ideal candidate combines strong process engineering fundamentals, hands-on manufacturing experience, and thrives in fast-paced, collaborative environments with continuous improvement culture.
