Manufacturing Engineer

Expand Reach Inc.; Aurora; On-site; CAD 90,000 - 120,000; Full time

Job summary

Expand Reach Inc. in Canada is seeking a Manufacturing Engineer to drive the transition of new products from design through pilot builds into full-scale production, developing, implementing, and validating manufacturing processes for both new and existing products.

The role partners with Product Engineering to drive DFM/DFA and cost optimization, while leading root cause analyses and Lean initiatives. Expect cross-functional collaboration across Engineering, Production, Quality, and Supply

Qualifications

• Degree in Electronics, Electrical, Manufacturing, Mechanical, Industrial Engineering, or a related discipline.
• 5+ years of Manufacturing Engineering experience in a low-volume, high-mix environment.
• Strong knowledge of DFM, DFA, GD&T, D/P-FMEA, process validation, and Root Cause Analysis.
• Familiarity with hardware testing and validation methodologies is an asset.

Responsibilities

• Lead the transition of new products from design through pilot builds into full-scale production.
• Develop, implement, and validate manufacturing processes for both new and existing products.
• Create and maintain manufacturing documentation, including Manufacturing BOMs, routings, work instructions, test procedures, PFMEA, cycle time standards, and tooling.
• Drive Design for Manufacturability (DFM) and Design for Assembly (DFA) with Product Engineering and cost optimization.
• Lead root cause investigations using structured problem-solving methodologies and implement corrective actions.
• Drive Lean Manufacturing initiatives to reduce waste, improve throughput, increase FPY and reduce COPQ.
• Lead cross-functional projects across Engineering, Production, Quality, Supply Chain and suppliers.
• Support ECOs, process validation, production readiness, and manufacturing cost estimates for quotations.
• Provide day-to-day manufacturing engineering support to production and address technical issues.
• Represent Manufacturing Engineering in technical meetings, customer discussions, and audits; travel to customer or supplier locations as required.

Skills

Analytical thinking

Cross-functional leadership

Project management

Excellent communication

Problem solving

Education

Bachelor's degree in Electronics, Electrical, Manufacturing, Mechanical, Industrial Engineering, or related discipline

Tools

SolidWorks

AutoCAD

MS Office Suite

ERP systems

BOM structures & routings

ECO processes

Job description

• Process Development & NPI: Lead the transition of new products from design through pilot builds into full-scale production, developing, implementing, and validating manufacturing processes for both new and existing products.
• Documentation & Standards: Create and maintain manufacturing documentation, including Manufacturing BOMs, routings, work instructions, test procedures, process flow diagrams, PFMEA, cycle time standards, equipment, fixtures, jigs, and tools.
• Design & Optimization: Partner with Product Engineering to drive Design for Manufacturability (DFM), Design for Assembly (DFA), and cost optimization.
• Quality & Root Cause Analysis: Lead root cause investigations using structured problem-solving methodologies (8D, 5 Why, Fishbone, etc.) and implement effective corrective and preventive actions.
• Continuous Improvement: Drive Lean Manufacturing initiatives to reduce waste, improve throughput, increase First Pass Yield (FPY), and lower Cost of Poor Quality (COPQ).
• Cross-Functional Leadership: Lead cross-functional projects involving Engineering, Production, Quality, Supply Chain, and suppliers to support product lifecycle improvements and cost reduction.
• Engineering & Production Support: Support Engineering Change Orders (ECOs), process validation, production readiness, and manufacturing cost estimates for quotations. Provide day-to-day manufacturing engineering support to production, resolving technical issues and improving process capability and equipment effectiveness.
• Stakeholder Representation: Act as the primary Manufacturing Engineering representative in technical meetings, customer discussions, and production readiness reviews. Support customer quotations, technical inquiries, and internal, customer, or third-party quality audits.
• Travel: Occasionally travel to customer or supplier locations as required.

Qualifications

• Education: Degree in Electronics, Electrical, Manufacturing, Mechanical, Industrial Engineering, or a related discipline.
• Experience: 5+ years of Manufacturing Engineering experience in a low-volume, high-mix manufacturing environment. Proven experience leading New Product Introduction (NPI) and process development.
• Technical Knowledge: Strong background in DFM, DFA, GD&T, D/P-FMEA, process validation, and Root Cause Analysis. Familiarity with hardware testing and validation methodologies is an asset.
• Systems & Tools: Proficient with SolidWorks and/or AutoCAD, Microsoft Office Suite (Excel, Word, PowerPoint, Visio), and ERP systems. Hands-on experience with BOM structures, routings, and ECO processes.
• Tooling Design: Experience designing manufacturing fixtures, tooling, and production aids.
• Core Competencies: Strong analytical, organizational, project management, and cross-functional leadership skills without direct authority. Excellent written and verbal communication skills.