Sr. Manufacturing Engineer, NPI Final Assembly

JOB SUMMARY:

As a Sr Manufacturing Engineer for New Product Introduction, you will define and implement the processes that enable high-quality, safe, and efficient final assembly production. You will be a partner with engineering, operations, and process technicians to develop documentation, tooling, standards, and workflows that support successful product launches. You will also help drive improvements in cost, quality, and manufacturability while ensuring production readiness for new and updated products. This role offers the opportunity to influence launch outcomes, strengthen manufacturing systems, and shape how new products transition from development to full-scale production

ESSENTIAL DUTIES & RESPONSIBILITIES:

• Work with Process Technicians to develop and maintain process documentation and work instructions to ensure accuracy and compliance.

• Plan and coordinate production activities necessary to produce specified new products, including builds, equipment and process validations, and production ramp-up.

• Conduct direct labor estimation based on CAD design and establish standards for operations.

• DFAM design evaluations to ensure designs meet best practice guidelines and ergonomic requirements.  Ability to provide constructive feedback to design engineers to resolve issues.

• Define tooling and fixturing requirements and collaborate with tool designers for procurement and implementation.

• Analyze manufacturing methods and standards and propose solutions to improve safety, quality, productivity, and cost.

• Ownership of writing and sign-off on all system level PFMEA’s for all new products launched.

• Identify and implement cost reduction initiatives, standard work development, and continuous improvements.

• Assist in equipment scope of work, specification, quoting and justification; review preliminary designs to optimize cost and quality.

• Prepare capital equipment expenditures, assist in vendor runoffs and site commissioning of equipment.

• Manage pre-production pilot build planning, execution, and post-build reporting

• Process tooling requisitions and maintain accurate procurement and project records.

• Ensure compliance with ergonomic and safety requirements for new processes and equipment.

• Participate in continuous improvement initiatives and complete company-provided training.

• Lead problem resolution activities, including root cause analysis, 8D, CAPA, and closure of corrective actions.

• Perform special projects and other duties assigned to support manufacturing and NPI objectives.

• Accountable to meet Polaris Development Process Milestone deliverables

• Create and maintain a standard cost model for new products to support launch decisions and make vs buy analysis.

• Core work is focused around “operator first” mindset, driving DFAM early in the design phase for simplification of vehicle assembly

SKILLS, KNOWLEDGE & EDUCATION:

• Education: B.S. in Mechanical, Manufacturing, Industrial Engineering, Mechatronics, Aeronautical Engineering, or related field.

• Preferred credentials: MBA or Project Management Certification (PMP) is desirable.

• Experience: Minimum 5 years in manufacturing engineering, with prior experience as a Process Engineer or similar role; experience in final assembly for aerospace, automotive, electronics, or electromechanical products preferred.

• Technical knowledge: Strong knowledge of manufacturing processes, assembly operations, PFMEA, control plans, SPC, and change management.

• Software skills: Proficiency in 3D Cad Software (SolidWorks/Creo), AutoCAD; advanced MS Office skills including MS Teams, Outlook, Excel, Powerpoint, Power BI, OneNote and MS Project.

• Project management: Strong project management skills and ability to lead cross‑functional initiatives.

• Analytical skills: Strong analytical and problem‑solving skills with a focus on continuous improvement.

• Communication: Excellent organizational, written, and verbal communication skills; ability to build rapport with U.S. and International‑based customers and internal stakeholders.

• Additional preferred skills: Experience with DFAM, PFMEA, automation, fixture/machinery design, electrical/functional testing

• Language: Fluent English.

WORKING CONDITIONS:

• Location: Research and Development Facility, Manufacturing plants; frequent plant presence required.

• Schedule: Availability for support during ramp-up and occasional non-standard hours or shifts.

• Travel: Up to 25% - Occasional travel to suppliers or manufacturing sites

• Reporting: Reports to NPI Staff Engineer.

• Environment: Work includes time on the production floor with exposure to typical manufacturing conditions; adherence to PPE and safety procedures required.

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