Manufacturing Engineer: Launch, Optimize & Scale

HCLTech; Boston (MA); On-site; USD 93,000 - 122,000; Full time

Job summary

HCLTech in Boston is seeking a Manufacturing Engineer to lead process development from concept to production launch and ramp-up. You will define line requirements, tooling, and documentation, while partnering across Engineering, Quality, and Operations to integrate manufacturing needs into the plant design.

The role requires hands-on shop-floor experience, strong knowledge of manufacturing processes, and a proven track record in launch readiness, PFMEA, and continuous improvement initiatives.

Qualifications

• Experience supporting greenfield manufacturing facility development, large-scale plant launch, or major capacity expansion programs.
• Hands-on experience with production line launch, equipment installation, commissioning, run-at-rate, ramp-up stabilization, and handover.
• Strong knowledge of manufacturing processes such as machining, fabrication, welding, sheet metal, assembly, testing, painting/coating, and finishing.
• Good understanding of engineering drawings, GD&T, tolerance stack-up, BOM structure, material specifications, and manufacturing feasibility assessment.
• Experience with PFMEA, control plans, APQP, PPAP, SPC, MSA, CAPA, 8D, process validation, production trials, process audits, and readiness reviews.
• Strong knowledge of OEE, cycle time, takt time, line balancing, bottleneck analysis, yield improvement, scrap reduction, cost reduction, and throughput improvement.
• Experience with PFEP, material flow, line-side delivery, packaging, sequencing, warehouse interfaces, and internal logistics.
• Familiarity with MES, ERP, SAP, Teamcenter, and manufacturing documentation control.
• Familiarity with lean manufacturing, continuous improvement, root-cause analysis, 5 Why, Fishbone, Pareto, 5S, standardized work, visual management, and structured problem-solving.
• Strong manufacturing process development and production launch capability.
• Hands-on shop-floor mindset with the ability to translate engineering requirements into practical production solutions.
• Ability to manage complex, cross-functional manufacturing issues from planning through execution.

Responsibilities

• Lead manufacturing process development from concept planning through production launch and ramp-up.
• Define production line requirements, workstation concepts, tooling and fixture needs, equipment interfaces, labor assumptions, process flows, and manufacturing documentation.
• Develop and maintain work instructions, SOPs, process flow diagrams, routings, standardized work, cycle time studies, production checks, and launch readiness checklists.
• Partner with Product Engineering, Operations, Quality, Equipment Engineering, Controls Engineering, Industrial Engineering, Layout Engineering, Supply Chain, Facilities, Construction, EHS, and Maintenance teams to integrate manufacturing requirements into the overall plant design.
• Provide manufacturing inputs to factory master planning, including line layout, equipment placement, operator movement, material presentation, utility needs, ergonomics, safety, maintainability, and scalability.
• Participate in design reviews and provide DFM/DFA feedback to improve manufacturability, assembly efficiency, serviceability, quality, and cost.
• Define workstation-level requirements, including assembly sequence, operator interface, torque strategy, fastening methods, error-proofing, gauges, lifting devices, tools, jigs, fixtures, and production aids.
• Support PFMEA, control plans, APQP/PPAP inputs, process validation, production trials, process audits, run-at-rate, launch readiness reviews, and production handover activities.
• Lead station readiness, tooling readiness, equipment readiness, manpower readiness, material readiness, process documentation readiness, and quality readiness for new production lines.
• Collaborate with Layout and Industrial Engineering teams to optimize line balance, operator movement, station design, material presentation, line-side storage, capacity, and production flow.
• Work with Equipment and Controls Engineering teams to ensure equipment, fixtures, automation, sensors, HMI, safety systems, and process controls meet manufacturing requirements.
• Support PFEP integration into manufacturing processes, including packaging strategy, sequencing, replenishment, point-of-use storage, line-side delivery, warehouse interfaces, and internal logistics.
• Support equipment installation, commissioning, debug, process validation, run-at-rate, ramp-up stabilization, and transition to stable operations.
• Analyze production performance using OEE, cycle time, downtime, yield, scrap, rework, labor utilization, first-time quality, defect trends, and throughput data.
• Lead root-cause analysis and corrective actions for issues related to process capability, line stoppages, quality defects, rework, scrap, ergonomics, equipment interaction, material flow, or operator efficiency.
• Drive continuous improvement and cost reduction initiatives using lean manufacturing, Kaizen, 5S, VSM, SMED, Poka-Yoke, standardized work, waste elimination, and structured problem-solving methods.
• EHS.

Skills

Manufacturing process development

Production launch

Cross-functional collaboration

DFM/DFA feedback

Lean manufacturing

OEE analysis

Root cause analysis

Data-driven decision making

Strong communication

Tools

PLM

SAP

ERP

MES

SCADA

Job description

HCLTech in Boston is seeking a Manufacturing Engineer to lead process development from concept to production launch and ramp-up. You will define line requirements, tooling, and documentation, while partnering across Engineering, Quality, and Operations to integrate manufacturing needs into the plant design.

The role requires hands-on shop-floor experience, strong knowledge of manufacturing processes, and a proven track record in launch readiness, PFMEA, and continuous improvement initiatives.