Lead Manufacturing Engineer, Joining - Design for Manufacturing and Assembly

The Role

As Lead Manufacturing Engineer, Joining, you'll be Mach's go-to expert on how our vehicles are held together: when to bolt, rivet, bond, or combine methods. You'll own torque tooling and adhesive dispense standards in Mach's prototype factory. That means selecting, buying and deploying the tools our technicians use to build every vehicle, and making sure each joint is tightened right, every torque curve is reported, and every bead of adhesive meets profile inspection criteria. 

You'll push the field forward through research and development (R&D) on new materials, hardware and processes; from designing experiments, to building test articles, partnering with suppliers and moving what works into production. This is a hands-on technical leadership role with direct reports. This role will work closely with Design Engineering, Vehicle Assembly ME, Prototype Factory operations, Quality, Supply Chain and Production to achieve overall production ramp goals across Mach’s factories.

Key Responsibilities

Own the Joining DFMA guide

• Write, publish and maintain Mach's Joining DFMA guide. It should cover:
  • design rules, with the reasoning and test data behind them
  • preferred fasteners, adhesives and joining processes
  • standard joint features and tolerances
  • worked examples and review checklists
• Own Mach's preferred fastener and adhesive lists. Cut unique part numbers and drive commonality across programs.
• Define joint design rules:
  • fasteners: preload and torque, edge distance and pitch, thread engagement, inserts and locking methods
  • galvanic compatibility
  • bondlines: overlap, thickness control and surface prep
• Set standards for automated fastening and dispensing: torque-angle monitoring, auto-feed fasteners, bead geometry and in-process inspection.
• Define the DFMA sign-off criteria for design gates and hold programs to them.
• Set and track DFMA metrics for each program, such as part count, unique fastener count, assembly time, first-pass yield and cost.
• Keep the guide current with test results, production lessons and supplier input. Train design and manufacturing engineers to apply it.

Own torque tooling in the prototype factory

• Own torque tooling procurement: write tool specs, choose vendors, run quotes, manage lead times and own the tooling budget.
• Deploy tools on the floor:
  • set up tool programs and torque strategies (torque, torque-angle, yield control)
  • connect tool controllers to the production tracking system (MES) so every result is recorded
• Build torque mistake-proofing into each station, such as socket selectors, fastener count checks, and interlocks that run the right tool program for each joint.
• Run the torque tool calibration and maintenance program. Verify tool capability on real joints and set residual (audit) torque checks with Quality.

Shape designs early

• Review vehicle architecture and material choices at concept, before designs lock, with an eye to how parts will be joined.
• Run DFMA studies at the part, assembly and system level, and give design teams specific feedback backed by data.
• Drive content reduction, simpler assembly and build-in-quality. Push for wider tolerances where performance allows, and for joints that suit automation.
• Lead value engineering on released designs: challenge assumptions and take out cost.

Enable trade studies and make vs. buy

• Set the rules for choosing adhesive, mechanical or hybrid joints.  Develop the data, cost models and decision criteria for adhesive-vs-fastener and other trade studies.
• Build should-cost, cycle-time and rate models that show how joining choices affect cost, capital investment, schedule and quality.

Lead R&D

• Set and run a joining R&D roadmap aimed at faster, cheaper, more reliable production.
• Plan and run designed experiments (DOE). Build coupons and test articles, test to failure, analyze results with sound statistics, and publish findings.
• Release proven processes to production.  Write process specs, and define qualification and acceptance criteria.

Required Qualifications 

• BS in Mechanical, Materials or Manufacturing Engineering, or equivalent experience.
• 7+ years of hands-on experience in fastener engineering, adhesive bonding or joining process engineering. This includes taking hardware from design into production at rate in automotive, aerospace, defense or consumer electronics.
• Deep knowledge of bolted joint analysis (for example, VDI 2230) and bonding science (surface prep, cure kinetics, failure modes).
• Hands-on experience selecting, specifying and deploying torque tooling, including:
• Hands-on joint testing (for example, ASTM D1002 lap shear and peel testing) and failure analysis.
  • DC electric nutrunners, pulse tools and transducerized wrenches
  • tool controllers and torque strategies
  • tool capability studies and calibration
• A track record of writing design standards, design guides or process specs.
• Strong manufacturing and industrial engineering fundamentals: cycle time analysis, OEE, process capability (Cp/Cpk), gauge R&R, DOE, error proofing, ergonomics and ROI.
• Working knowledge of GD&T (ASME Y14.5), tolerance stack-ups and DVA.
• Skilled in 3D CAD (NX, CATIA, SolidWorks or similar).

Preferred Qualifications

• MS or PhD in Materials Science, Mechanical Engineering or a related field.
• Experience with major torque tool platforms (for example, Atlas Copco, Desoutter, Cleco or Stanley) and connecting tool data to an MES.
• Knowledge of torque tool standards, such as ISO 6789 for hand torque tools and ISO 5393 for power tool performance.
• Experience setting up tooling in a new prototype or production factory, including owning the equipment budget.
• Experience with aerospace fastener standards (NAS, NASM, MS).
• Experience with automotive high-volume joining (self-piercing rivets, flow-drill screws, structural adhesives).
• Nondestructive inspection (NDI) of bonded joints.
• Formal DFMA methods (for example, Boothroyd Dewhurst), should-cost modeling.
• Experience leading DFMEAs and PFMEAs.
• Patents, publications, or processes you developed and put into production.
• Experience standing up a lab, test capability, production line at a fast-moving company.
• Experience in an AS9100 or defense production environment.
• Lean or Six Sigma certification.

Additional Requirements

• Available to work extended hours and weekends as needed.

ITAR Requirements

To conform to U.S. Government export regulations, applicant must be a (i) U.S. citizen or national, (ii) U.S. lawful, permanent resident (aka green card holder), (iii) Refugee under 8 U.S.C. § 1157, or (iv) Asylee under 8 U.S.C. § 1158, or be eligible to obtain the required authorizations from the U.S. Department of State. Learn more about the ITAR here.  

Senior Engineer 140000 - 180000 USD