Manufacturing Engineer - Automated Assembly

Flex; Buffalo Grove (IL); On-site; USD 110,000 - 150,000; Full time

Job summary

Flex is seeking a Manufacturing Engineer - Automated Assembly to optimize high-speed automated lines, improve OEE, yield and quality in a fast-paced environment.

Responsibilities include line balancing, time studies, preventive maintenance planning, RCA, PFMEA and control plans, plus Kaizen events and documentation to support ramp-up and cost reduction. Cross-functional collaboration with Quality, Maintenance and Supply Chain is essential.

Qualifications

• Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, or related field.
• 7+ years of manufacturing experience in high-speed automated assembly.
• Hands-on experience with automation systems (Vision / Cognex), robotics, and PLC-controlled equipment.
• Strong knowledge of Lean Manufacturing and Six Sigma (Green Belt preferred).
• Experience with PFMEA, control plans, and validation methods.
• Familiarity with servo motion control and sensors, and reading schematics/drawings.

Responsibilities

• Optimize cycle time, throughput, and Overall Equipment Effectiveness (OEE).
• Perform line balancing, time studies, and capacity analysis.
• Develop preventive maintenance strategies with maintenance teams.
• Troubleshoot mechanical, electrical, and process issues to minimize downtime.
• Implement process controls (SPC, poka-yoke, error-proofing).
• Lead root cause analysis (RCA) for defects and implement corrective actions.
• Support PFMEA, control plans, and validation (IQ/OQ/PQ).
• Drive Lean Manufacturing and Six Sigma initiatives.
• Lead Kaizen events and cost-reduction projects.
• Develop process documentation, work instructions, and training materials.
• Support pilot builds and production ramp-up.
• Analyze production data to identify trends and opportunities.
• Monitor KPIs such as yield, uptime, cycle time, and scrap rates.
• Interface with Quality, Maintenance, Supply Chain, and Production teams.

Skills

7+ years experience

Lean Manufacturing

Six Sigma Green Belt

Analytical/problem-solving

Cross-functional communication

Education

Bachelor's degree in Mechanical Engineering / Manufacturing Engineering / Industrial Engineering

Tools

Vision / Cognex

Robotics

PLC-controlled equipment

CAD tools

Manufacturing analysis software

Job description

Flex is the diversified manufacturing partner of choice that helps market-leading brands design, build and deliver innovative products that improve the world. A career at Flex offers the opportunity to make a difference and invest in your growth in a respectful, inclusive, and collaborative environment.

PURPOSE:

The Manufacturing Engineer - Automated Assembly is responsible for optimizing, and sustaining automated, high-throughput assembly processes. This role focuses on maximizing equipment efficiency, yield, and product quality while supporting continuous improvement initiatives in a fast-paced production environment.

PRINCIPLE ACCOUNTABILITIES/DUTIES:

• Optimize cycle time, throughput, and Overall Equipment Effectiveness (OEE).
• Perform line balancing, time studies, and capacity analysis.
• Develop preventive maintenance strategies in collaboration with maintenance teams.
• Troubleshoot mechanical, electrical, and process-related issues to minimize downtime.
• Implement process controls (SPC, poka-yoke, error-proofing).
• Lead root cause analysis (RCA) for defects and implement corrective/preventive actions.
• Support PFMEA, control plans, and validation (IQ/OQ/PQ).
• Drive Lean Manufacturing and Six Sigma initiatives.
• Reduce waste, scrap, and cycle inefficiencies.
• Lead Kaizen events and cost-reduction projects.
• Develop process documentation, work instructions, and training materials.
• Support pilot builds and production ramp-up.
• Analyze production data to identify trends and improvement opportunities.
• Monitor KPIs such as yield, uptime, cycle time, and scrap rates.
• Implement digital manufacturing tools and MES integration where applicable.
• Work with Quality, Maintenance, Supply Chain, and Production teams.
• Interface with external suppliers and equipment integrators.

QUALIFICATIONS:

• Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, or related field.
• 7+ years of manufacturing industry experience in high-speed automated assembly, e.g. SMT, medical devices (ideal), electronics, automotive, defense/aerospace, pharmaceutical, or consumer products).
• Hands-on experience with automation systems (Vision / Cognex), robotics, and PLC-controlled equipment.
• Strong knowledge of Lean Manufacturing, Six Sigma (Green Belt preferred).
• Experience with PFMEA, control plans, and validation methods.
• Familiarity with servo motion control and sensors.
• Must have experience troubleshooting and fixing mechanical systems, e.g. gear boxes, PLCs, etc. ; Fixing system-related issues (e.g. line PC shut-downs, etc.).
• Experience reading schematics and drawings, a must.
• Proficiency in CAD tools and manufacturing analysis software.
• Strong analytical and problem-solving skills.
• Ability to work in a fast-paced, high-volume production environment.
• Effective communication (verbal and written), interpersonal / cross-functional collaboration, and organizational skills, all required.

WORK ENVIRONMENT:

• Clean Room Manufacturing Environment
• High-volume manufacturing floor with automated assembly lines
• Exposure to fast-moving machinery and robotics
• May require occasional travel for equipment sourcing or vendor support

Flex is an Equal Opportunity Employer and employment selection decisions are based on merit, qualifications, and abilities. We do not discriminate based on: age, race, religion, color, sex, national origin, marital status, sexual orientation, gender identity, veteran status, disability, pregnancy status, or any other status protected by law. We're happy to provide reasonable accommodations to those with a disability for assistance in the application process. Please email [e-mail] and we'll discuss your specific situation and next steps (NOTE: this email does not accept or consider resumes or applications. This is only for disability assistance. To be considered for a position at Flex, you must complete the application process first).