Manufacturing Process Design, Senior Leader

Vertiv; Thane; On-site; INR 14,286,000 - 18,095,000; Full time

Job summary

Vertiv is seeking a Manager / Senior Leader of Manufacturing Process Design to architect our production ecosystems and lead the Virtual-to-Physical transition for power and thermal products. You will bridge R&D and shop floor, using high-fidelity DES and Yamazumi to optimize lines before production.

You will guide design for manufacturability, drive continuous improvement with Six Sigma, and mentor a team of engineers across global design centers and local plants.

Qualifications

• Bachelor’s degree in Industrial Engineering, Systems Engineering, Operations Research, Mechanical, Electrical or Manufacturing Engineering.
• Master’s degree in Industrial & Systems Engineering (ISE) or Data Analytics is highly preferred.
• Minimum 15+ years of hands-on experience in manufacturing process design for power products and leadership roles.

Responsibilities

• Lead NPI design integration with R&D at earliest design stages, embedding manufacturing constraints.
• Balance processes to TakTime using Yamazumi and eliminate bottlenecks for synchronized flow.
• Translate data into DES models with MTBF/MTTR and cycle times to validate targets.
• Lead DFM/DFA reviews to reduce ECOs post-launch.
• Conduct virtual commissioning and IQ/OQ/PQ validations for equipment.
• Perform root cause analysis using FMEA and Six Sigma for continuous improvement.
• Coordinate cross-functional launches and cradle-to-grave handoffs to production.
• Mentor engineers in Yamazumi, DFM/DFA and advanced manufacturing tech.

Skills

Simulation modeling

Takt time

Yamazumi

ERP/MES integration

English

Spanish

Communication

Education

Bachelor's degree in Industrial Engineering or related

Master's degree in Industrial & Systems Engineering or Data Analytics (preferred)

Tools

SolidWorks

AutoCAD

FlexSim

Arena

Simio

AnyLogic

Power BI

Tableau

Job description

Vertiv is seeking a Manager / Senior Leader of Manufacturing Process Design to act as the lead architect of our production ecosystems. In this role, you will be responsible for the "Virtual-to-Physical" transition of our Power and Thermal products, serving as the primary bridge between R&D and the shop floor. By integrating Full-Line Balancing with high-fidelity Discrete Event Simulation (DES), you will ensure that our manufacturing lines are mathematically optimized for maximum efficiency long before the start of production. This role requires a blend of deep industrial engineering expertise, leadership acumen, and advanced data modeling to drive a "Right First Time" global launch strategy.

Position Summary

JOB DESCRIPTION

Vertiv is seeking a Manager / Senior Leader of Manufacturing Process Design to act as the lead architect of our production ecosystems. In this role, you will be responsible for the "Virtual-to-Physical" transition of our Power and Thermal products, serving as the primary bridge between R&D and the shop floor. By integrating Full-Line Balancing with high-fidelity Discrete Event Simulation (DES), you will ensure that our manufacturing lines are mathematically optimized for maximum efficiency long before the start of production. This role requires a blend of deep industrial engineering expertise, leadership acumen, and advanced data modeling to drive a "Right First Time" global launch strategy.

Responsibilities

• Up-Front Design Integration: Lead the New Product Introduction (NPI) process by collaborating with R&D at the earliest design stages. Ensure manufacturing constraints, plant capabilities, and automation requirements are integrated into the product DNA before design freeze.
• Synchronized Process Design & Bottleneck Neutralization: Drive operational excellence through rigorous Yamazumi modeling, ensuring all manufacturing processes are perfectly balanced to Takt time. By neutralizing bottlenecks and bridging disconnected "islands of automation," you will create a seamless, synchronized flow that eliminates process unevenness and waste, minimizing WIP and maximizing plant-wide throughput.
• Data-Driven Simulation (DES): Oversee the translation of Yamazumi work-content data and line-balancing profiles into Discrete Event Simulation models. Capture granular process data—including MTBF, MTTR, and precise step-level cycle times—to virtually "stress test" the production environment and validate throughput targets before physical implementation.
• Proactive DFM/DFA Leadership: Direct the execution of rigorous Design for Manufacturing (DFM) and Design for Assembly (DFA) reviews. Act as the final gatekeeper for manufacturability, identifying assembly risks early to reduce engineering change orders (ECOs) post-launch.
• Virtual Commissioning & Validation: Utilize simulation tools to perform "What-If" analysis on proposed line layouts, accounting for variable demand and supply chain lags. Oversee the selection and validation (IQ/OQ/PQ) of manufacturing equipment specific to power electronics.
• Root Cause & Continuous Improvement: Lead root cause analysis for production issues using FMEA and Six Sigma. Establish a feedback loop where real-time plant floor data from BackEnd/ERP systems updates to feed into the simulation models for continuous optimization.
• Cross-Functional Launch Orchestration: Drive alignment between global design centers and local plant operations. Serve as the technical management lead during the "Cradle-to-Grave" lifecycle to ensure a flawless handoff to production teams.
• Team Leadership & Mentorship: Manage and mentor a team of engineers, fostering best practices in Yamazumi modeling, DFM/DFA, and advanced manufacturing technologies.

Skills

• Advanced Simulation Modeling: Expert-level capability in building and interpreting Discrete Event Simulation models to justify CAPEX and process changes.
• Industrial Engineering Toolkit: Mastery of Takt time analysis, Work Content Graphing, and Yamazumi work-balancing techniques.
• Executive Communication: Proficient in presenting complex simulation data, project timelines, and ROI projections to senior leadership.
• Systems Integration: Familiarity with ERP (SAP) and MES environments, with an understanding of how to structure "simulation-ready" manufacturing metadata.
• Bilingual Proficiency: Professional fluency in English and Spanish to facilitate global technical collaboration and cross-regional manufacturing support.

EDUCATION AND CERTIFICATIONS

• Degrees: Bachelor’s degree in Industrial Engineering, Systems Engineering, Operations Research, Mechanical Engineering, Electrical Engineering, or Manufacturing Engineering.
• A Master’s degree in Industrial & Systems Engineering (ISE) or Data Analytics is highly preferred. Experience: Minimum of 15+ years of hands-on experience in manufacturing process design for power products (UPS, DC power systems, or similar complex electronics), including experience in a leadership or project management capacity.
• Proven Launch Track Record: Demonstrated success applying DFM/DFA and high-fidelity simulation modeling to reduce manufacturing costs and improve reliability in high-volume, international environments.
• Software Proficiency: Expert in CAD software (SolidWorks, AutoCAD) and Advanced Simulation tools (e.g., FlexSim, Arena, Simio, or AnyLogic). Proficiency in data visualization tools (Power BI/Tableau).
• Lean Mastery: Extensive experience with lean manufacturing principles, specifically Yamazumi (Work Balance) modeling, Kaizen events, and the mathematical removal of process waste.
• Certification (Preferred): Six Sigma Black Belt, Lean Manufacturing Certification, or Professional Engineering (PE) license.

Physical Requirements

No Special Physical Requirements

ENVIRONMENTAL DEMANDS

No Special Requirements

Travel Time Required

• 25%

About The Team

Work Authorization

No calls or agencies please. Vertiv will only employ those who are legally authorized to work in the United States. This is not a position for which sponsorship will be provided. Individuals with temporary visas such as E, F-1, H-1, H-2, L, B, J, or TN or who need sponsorship for work authorization now or in the future, are not eligible for hire.

Equal Opportunity Employer

We promote equal opportunities for all with respect to hiring, terms of employment, mobility, training, compensation, and occupational health, without discrimination as to age, race, color, religion, creed, sex, pregnancy status (including childbirth, breastfeeding, or related medical conditions), marital status, sexual orientation, gender identity / expression (including transgender status or sexual stereotypes), genetic information, citizenship status, national origin, protected veteran status, political affiliation, or disability.