Manufacturing Engineer

Aerostar Mfg; Romulus (MI); On-site; USD 110,000 - 140,000; Full time

Job summary

Aerostar Manufacturing seeks a Senior Manufacturing Engineer to lead new product development, implement manufacturing processes, and drive continuous improvement. The role coordinates with customers, engineering, quality, operations, and suppliers to ensure successful launches and manufacturability.

You will oversee design reviews, feasibility discussions, and production readiness while mentor­ing a team of engineers and technicians.

Qualifications

• Bachelor’s degree in engineering or related field.
• Minimum 810 years of manufacturing engineering experience in automotive or related environment.
• Minimum 3 years of engineering leadership or supervisory experience.
• Experience leading customer DQR and feasibility reviews.
• Knowledge of APQP, PPAP, GD&T, PFMEA, Control Plans, Process Flow Development, Root Cause Analysis, Lean Manufacturing and CI methods.

Responsibilities

• Lead APQP activities from product launch through production.
• Prepare, review, and approve PPAP documentation.
• Review drawings and CAD models using GD&T.
• Develop manufacturing docs, work instructions and process specs.
• Support internal, customer, and third‑party audits.
• Ensure compliance with IATF 16949 and customer requirements.
• Mentor and develop engineering staff and drive continuous improvement.

Skills

DQR leadership

APQP

PPAP

GD&T

PFMEA

Control Plans

Process Flow

Root Cause Analysis

Lean Manufacturing

CI methodologies

8D problem solving

Manufacturing Process Development

Leadership

Education

Bachelor’s Degree in Manufacturing/Mechanical/Industrial Engineering

Tools

CAD software

ERP/MRP/MES

Job description

Aerostar Manufacturing is seeking an experienced and highly motivated Senior Manufacturing Engineer to provide technical leadership for new product development, manufacturing process implementation, and continuous improvement initiatives. This position serves as a key liaison between customers, engineering, quality, operations, and suppliers to ensure successful product launches while meeting customer, quality, and business objectives.

The Senior Manufacturing Engineer will represent Aerostar Manufacturing during Customer Design Quality Review (DQR) meetings, providing manufacturing expertise and ensuring product designs are optimized for manufacturability, quality, cost, and production readiness.

In addition to technical responsibilities, this position is a people leadership role with direct supervisory responsibility for four (4) or more Manufacturing Engineers and/or Engineering Technicians. The successful candidate will mentor, coach, develop, and manage the engineering team while driving accountability, performance, and continuous improvement throughout the department.

Customer & Technical Leadership

• Attend and actively support customer Design Quality Review (DQR) meetings.
• Represent Manufacturing Engineering during customer technical reviews, feasibility reviews, and product development meetings.
• Collaborate with customers, Design Engineering, Program Management, Quality, Operations, and suppliers to ensure successful product launches.
• Work closely with Engineering Lead in India to understand and use data from supplier Technical Reviews/Feasibility Analysis for DQR inputs.
• Evaluate product designs for manufacturability and recommend design improvements that improve quality, reduce cost, and minimize manufacturing risk.
• Lead manufacturing feasibility reviews for new products, engineering changes, and quoting activities.
• Develop and implement robust manufacturing processes that support safety, quality, delivery, and productivity goals.
• Support equipment selection, tooling design, process validation, and production readiness activities.
• Support root cause investigations and corrective actions using structured problem‑solving methodologies. (8D, Fishbone, etc.)
• Drive Lean Manufacturing and continuous improvement initiatives throughout production operations.

Quality & Launch Responsibilities

Serve as the Manufacturing Engineering subject matter expert for all AIAG Core Tools including:

• Advanced Product Quality Planning (APQP)
• Production Part Approval Process (PPAP)
• Geometric Dimensioning & Tolerancing (GD&T)
• Process Flow Diagrams
• PFMEA Development
• Control Plans
• Manufacturing Readiness Reviews
• Process Validation
• Launch Readiness Activities

Responsibilities include:

• Lead APQP activities from product launch through production.
• Prepare, review, and approve PPAP documentation.
• Review engineering drawings and CAD models utilizing GD&T principles.
• Develop manufacturing documentation including work instructions, process specifications, and standard work.
• Support internal, customer, and third‑party audits.
• Ensure compliance with IATF 16949 and customer‑specific requirements.

Leadership & People Management

This position has direct supervisory responsibility for four (4) or more Manufacturing Engineers and Engineering Technicians.

Leadership responsibilities include:

• Manage daily workload, priorities, and assignments for the Manufacturing Engineering team.
• Establish individual performance expectations and hold team members accountable for results.
• Conduct performance evaluations, coaching sessions, and career development planning.
• Mentor junior engineers by developing their technical knowledge and leadership capabilities.
• Provide guidance in manufacturing processes, APQP, PPAP, GD&T, PFMEA, problem solving, and engineering best practices.
• Foster collaboration across Engineering, Quality, Operations, Supply Chain, and Program Management.
• Support recruiting, interviewing, onboarding, and training of new engineering personnel.
• Promote a culture of continuous improvement, accountability, teamwork, and operational excellence.
• Ensure engineering resources are effectively allocated to support customer and business priorities.

Required Qualifications

• Bachelor’s Degree in Manufacturing Engineering, Mechanical Engineering, Industrial Engineering, or related engineering discipline.
• Minimum 810 years of manufacturing engineering experience in an automotive or related manufacturing environment.
• Minimum 3 years of engineering leadership or supervisory experience managing technical personnel.
• Demonstrated experience leading customer Design Quality Reviews (DQR), technical reviews, and manufacturing feasibility discussions.
• xtensive knowledge of:
• Extensive knowledge of:
  • APQP
  • PPAP
  • GD&T (ASME Y14.5)
  • PFMEA
  • Control Plans
  • Process Flow Development
  • Root Cause Analysis
  • Lean Manufacturing
  • Continuous Improvement methodologies
• Strong understanding of machining, castings/forgings, assembly, tooling, and manufacturing process development.
• Experience working directly with OEM and Tier 1 automotive customers.
• Excellent communication, presentation, and leadership skills.
• Strong project management and organizational abilities..

Preferred Qualifications

• Lean Six Sigma Green Belt or Black Belt certification.
• GD&T Professional Certification.
• Experience with ERP, MRP, and Manufacturing Execution Systems (MES).
• Experience with CAD software and manufacturing process simulation.
• Knowledge of AI-enabled engineering tools, digital manufacturing, and data-driven process improvement.

Core Competencies

• Engineering Leadership
• Customer Relationship Management
• Manufacturing Process Development
• PPAP & Quality Systems
• GD&T Expertise
• Technical Problem Solving
• Strategic Thinking
• Cross-Functional Collaboration
• Communication & Presentation Skills
• Decision Making
• Accountability & Performance Management.

Why Join Aerostar Manufacturing?

At Aerostar Manufacturing, our engineering team is instrumental in delivering innovative manufacturing solutions that exceed customer expectations. We are committed to developing technical leaders who drive operational excellence, foster continuous improvement, and build high‑performing engineering teams. As a Senior Manufacturing Engineer, you will have the opportunity to influence product development, lead customer engagements, manage and develop a talented engineering team, and play a critical role in the continued growth and success of our organization.