Lean Manufacturing Engineer II: Process & Flow Optimizer

PowerSecure, Inc.; Durham (NC); Hybrid; USD 85,000 - 120,000; Full time

Benefits offered by this job

Medical insurance

401(k) match

Paid time off (PTO)

Flexible spending accounts

Job summary

PowerSecure, Inc. in Durham, NC is seeking a Manufacturing Engineer II to improve Methods of Manufacture, Lean initiatives, and standardized work instructions on the shop floor. You will collaborate across teams to ensure designs are manufacturable and layouts are optimized for efficiency.

Responsibilities include leading 5S, value stream mapping, time studies, and capacity analyses while supporting BOM setups and CAD layout updates. Strong problem-solving and hands-on experience are essential.

Qualifications

• Bachelor’s degree in Engineering; Industrial or Mechanical preferred.
• 4+ years manufacturing experience with Lean/Continuous Improvement; Green Belt certification preferred
• Experience in assembly of generator sets, switchgear, and/or metal fabrication equipment preferred (discrete manufacturing experience highly desired)
• Strong problem-solving skills using engineering principles and techniques
• Hands-on production shop floor experience
• Effective communication skills, especially when resolving assembly issues with production teams
• Proficient in Microsoft Office, CAD systems, data analysis, and database tools
• Experience with facility layout design using AutoCAD
• Basic understanding of ERP systems (IFS preferred)
• Ability to read and interpret drawings, 3D models, specification sheets, and shop orders
• Solid understanding of flow diagrams, Value Stream Mapping (VSM), PFMEAs, and layout design
• Results-driven, with the ability to build strong relationships and manage multiple projects simultaneously
• Self-starter with a strong sense of urgency and ownership
• Understanding of integrating automation and AI into manufacturing processes
• Basic knowledge of G-code

Responsibilities

• Collaborate cross-functionally across departments to support operational goals
• Lead shop floor 5S initiatives
• Develop and improve processes, including Standard Work, SOPs, work instructions, and flowcharts
• Analyze data to identify waste and process bottlenecks
• Lead Lean activities such as Kaizen events, Value Stream Mapping (VSM), and process mapping
• Design and optimize work center layouts to improve use of space, materials, personnel, and equipment
• Support Bill of Materials (BOM) setup, including product structure and routings
• Maintain and update facility layouts in CAD to reflect improvements, relocations, and growth
• Conduct time studies and observations as needed
• Perform capacity analysis and drive material flow improvements (e.g., pacing charts, methods of manufacturing)
• Partner with Material Planning to enhance material flow (e.g., Kanban, point-of use storage)
• Collaborate with METs on product improvements, including DFMA, machine capabilities, tooling aids, and poka-yoke solutions
• Provide hands‑on support to the shop floor on manufacturing processes
• Develop solutions and recommendations for leadership to address manufacturing challenges
• Promote and reinforce a Lean manufacturing culture
• Design and develop tools and equipment to improve process efficiency
• Nest parts for fabrication equipment such as lasers, water jets, and copper punch machines

Job description

PowerSecure, Inc. in Durham, NC is seeking a Manufacturing Engineer II to improve Methods of Manufacture, Lean initiatives, and standardized work instructions on the shop floor. You will collaborate across teams to ensure designs are manufacturable and layouts are optimized for efficiency.

Responsibilities include leading 5S, value stream mapping, time studies, and capacity analyses while supporting BOM setups and CAD layout updates. Strong problem-solving and hands-on experience are essential.