Senior Manufacturing Engineer

Position Summary

IEM is currently seeking a Senior Manufacturing Engineer for our San Antonio, TX location and will report into the Director of Manufacturing Engineering. The Senior Manufacturing Engineer is a key technical leader responsible for driving strategic initiatives and delivering robust, scalable, and cost-effective manufacturing solutions. This role oversees the development, optimization, and support of advanced manufacturing processes, with a focus on operational excellence, automation, and continuous improvement. The Senior Engineer will lead cross-functional efforts to implement cutting-edge technologies, ensure regulatory compliance, and achieve world-class performance in quality, safety, and throughput. This position demands deep expertise in Lean, Six Sigma, process validation, and smart manufacturing systems, as well as strong leadership and mentoring capabilities.

Key Responsibilities

• Lead the design, development, and deployment of advanced manufacturing processes and production systems across new and existing product lines.
• Drive automation and Industry 4.0 initiatives to enable smart, data-driven manufacturing and improve operational agility.
• Serve as the technical authority in cross-functional teams involving operations, quality, R&D, and supply chain to ensure product manufacturability, scalability, and cost-effectiveness.
• Facilitate and lead high-impact kaizen events, root cause investigations (RCA), and the implementation of corrective/preventive actions (CAPA).
• Develop and maintain comprehensive documentation including process flow diagrams, SOPs, work instructions, and training guides to ensure consistency and compliance.
• Optimize production line layouts, material flow, and takt time using Lean methodologies to increase efficiency and reduce waste.
• Own and drive continuous improvement of key performance indicators (KPIs) such as yield, cycle time, scrap rate, and OEE (Overall Equipment Effectiveness).
• Lead capital project initiatives including equipment selection, procurement, commissioning, and validation (IQ/OQ/PQ).
• Ensure all processes and equipment meet applicable safety, quality, and regulatory standards (e.g., ISO, UL, OSHA, FDA as applicable).
• Champion cost reduction strategies through design for manufacturability (DFM), value engineering, and process automation.

Qualifications

• Bachelor’s degree in Mechanical, Industrial, or Manufacturing Engineering; Master’s degree or advanced technical certifications (e.g., Lean Six Sigma Black Belt) strongly preferred.
• 7–10+ years of progressive experience in a manufacturing engineering role, ideally within high-volume or complex electromechanical production environments.
• Proven expertise in Lean Manufacturing, Six Sigma, Standard Work, process mapping, and statistical process control (SPC).
• Proficient with CAD software, ERP systems, and manufacturing execution systems (MES); experience with digital manufacturing tools and data analytics is a plus.
• Demonstrated hands-on experience with automation systems, robotics, PLCs, machine vision, or other Industry 4.0 technologies.
• Strong leadership, communication, and project management skills, with a track record of cross-functional collaboration and mentoring junior engineers.
• Demonstrated career ambition with a track record of growth and increasing responsibility; highly promotable with the potential to take on broader leadership roles within a fast-paced, high-growth organization
• Strategic thinker with a continuous improvement mindset and a passion for driving operational excellence.