Lead Manufacturing Engineer - Design for Manufacturing and Assembly, Tooling Design

The Role

As Lead Manufacturing Engineer, Tooling Design, you'll be Mach's go-to expert on two things: how we design tooling, and how parts are designed so automation can handle, locate and assemble them. You'll push the field forward through research and development (R&D) on new materials, hardware and processes. You'll design experiments, build test articles, partner with suppliers and move what works into production. This is a hands-on technical leadership role with direct reports.

Key Responsibilities

Own the Tooling and Design-for-Automation guide

• Write, publish and maintain Mach's Tooling and Design-for-Automation guide. It should cover:
• design rules, with the reasoning and test data behind them
• preferred tooling components, materials and automation approaches
• standard locating features and tolerances
• worked examples and review checklists
• Write tooling standards: datum and locating strategy, modular fixture components, clamping, materials and documentation.
• Write design-for-automation rules for parts: gripping and locating features, part presentation and feeder compatibility, robot and tool access
• Set metrology and tooling verification standards (laser tracker, CMM, vision), and oversee checking fixtures and gauges.
• 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, assembly time, automation rate, tooling cost and lead time, and first-pass yield.
• Keep the guide current with test results, production lessons and supplier input. Train design and manufacturing engineers to apply it.

Shape designs early

• Review vehicle architecture and material choices at concept, before designs lock. Focus on datums, locating and automated handling.
• Run DFMA studies at the part, assembly and system level, and give design teams specific feedback backed by data.
• Lead static and kinematic assembly studies (virtual builds) to check robot reach, tool access, clearance and install paths before hardware exists.
• Drive content reduction, simpler assembly, build-in-quality and ergonomic access. Push for wider tolerances where performance allows, and for features that suit automation.
• Lead value engineering on released designs: challenge assumptions and take out cost.

Enable trade studies and make vs. buy

• Give the Vehicle Assembly ME team tooling cost, lead-time, capital and rate data for automation trades (manual vs. semi-automated vs. fully automated). Provide the same for make-vs-buy decisions on tooling and automation equipment.
• Build should-cost and rate models that show how design and automation choices affect cost, capital investment, schedule and quality.
• Write the requirements in RFQ packages for tooling and automation, and help evaluate supplier quotes.

Lead R&D

• Set and run a tooling and automation R&D roadmap aimed at faster, cheaper, more reliable production.
• Lead R&D on reconfigurable and low-cost fixturing, additive tooling, fixtureless and vision-guided assembly, and robotic drilling and fastening.
• Plan and run designed experiments (DOE). Build test articles and prototype cells, analyze results with sound statistics, and publish findings.
• Capture the inventions you develop and work with Legal to patent them.
• Design and deliver prototype tooling for development and validation builds, and lead manufacturing trials to prove new processes on real hardware.
• Release proven processes to production. Write process specs, and define qualification and acceptance criteria. Show process capability (Cp/Cpk) and measurement capability (GR&R), and set inspection methods with Quality.

Own the tool life cycle and support suppliers

• Own the life cycle of critical tools: feasibility and simulation, design, build, buyoff at the supplier, delivery and handoff to production.
• Design and oversee the build of critical fixtures, jigs, end effectors and assembly tooling.
• Run tool design reviews and buyoffs at tool shops. 
• Bring tooling expertise to design and process FMEAs (DFMEAs and PFMEAs). Maintain a library of known failure modes and proven controls.
• Lead root cause analysis on tooling-related escapes and repeat defects. Mentor engineers and help build Mach's DFMA function.

Required Qualifications 

• BS in Mechanical, Manufacturing or Industrial Engineering, or equivalent experience.
• 8+ years designing production tooling, fixtures or end effectors for automated or high-rate assembly in aerospace, automotive, defense or consumer electronics.
• Expert in GD&T (ASME Y14.5), datum schemes, and tolerance stack-ups across parts and tooling, including dimensional variation analysis.
• Experience integrating tooling with robots and automated cells, including selecting equipment and justifying ROI.
• 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.
• Skilled in 3D CAD (NX, CATIA, SolidWorks or similar).
• A first-principles thinker with a bias for action, who challenges assumptions with data.
• Comfortable on the production floor and in the lab, not just at a desk.
• A clear writer who can influence design decisions.

Preferred Qualifications

• Journeyman Tool and Die Maker certification or an equivalent toolmaker background.
• MS in Mechanical or Manufacturing Engineering or a related field.
• Experience with both aerospace assembly tooling and automotive assembly automation.
• Familiarity with PLCs, robot programming and machine safety standards.
• Large-scale metrology.
• Formal DFMA methods (for example, Boothroyd Dewhurst), should-cost modeling, and value engineering programs with measured savings.
• Experience with assembly and robot simulation tools (for example, Siemens Process Simulate or DELMIA).
• Experience leading DFMEAs and PFMEAs.
• Patents, publications, or processes you developed and put into production.
• 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