Manufacturing Engineer – Module Frames

Nextpower; Lexington (VA); On-site; USD 120,000 - 170,000; Full time

Job summary

Nextpower, a renewable energy technology leader, seeks a Manufacturing Engineer – Module Frames to drive concurrent engineering, supplier readiness, and industrialization of steel frame components across a global supply base. You will influence design for manufacturability and lead critical change implementations.

This role partners with R&D, Quality, Program Management and Procurement to ensure designs are cost-effectivе, scalable and reliable, while delivering through rigorous analysis,

Qualifications

• Bachelor’s degree in an Engineering discipline from an accredited institution with 10+ years of relevant experience.
• Experience in manufacturing engineering / industrialization for complex roll-formed steel components.
• 10+ years in design for manufacturing and steel processes; CAPEX project leadership.
• 5+ years serving large OEM customers in renewable energy or industrial manufacturing (solar experience a plus).
• Experience with concurrent engineering (DFM/DFMA) and factory validation.
• Experience with roll forming complex steel shapes and related processes (stamping, welding, laser cutting, machining).
• Experience leading supplier-facing engineering activities and change management in a PLM system.
• CAD collaboration for manufacturability reviews (SolidWorks or equivalent).
• Lean/Six Sigma knowledge and structured problem solving (8D, 5-Why, Pareto).
• Willingness to travel 75% (international and domestic).

Responsibilities

• Support launch and ramp-up of new equipment at supplier locations domestically and internationally.
• Provide manufacturing feasibility input and DFM/DFMA recommendations with suppliers.
• Review drawings to identify manufacturability risks and propose solutions.
• Lead manufacturing tech readiness for steel roll forming and related processes.
• Plan prototype builds, supplier trials, and on-site validations with measurement methods.
• Drive cost-reduction initiatives across module frames while maintaining performance.
• Define manufacturing readiness deliverables such as process flows and inspection approaches.
• Conduct supplier factory readiness audits and drive corrective actions.
• Provide rapid escalation support and root-cause analysis (8D, 5-Why).
• Document best practices and deploy across regions and suppliers.

Skills

Communication in English

Project management

Analytical thinking

Negotiation

Education

Bachelor’s degree in Engineering

Tools

SolidWorks

PLM system

Job description

Job Description

Job Title: Manufacturing Engineer – Module Frames

Location: Remote

Reports To: Manager, Manufacturing Engineering – Module Frames

Job Summary

At Nextpower, we are accelerating the world’s transition to renewable energy through intelligent solar tracking and breakthrough engineering. As a Manufacturing Engineer – Module Frames you will be a critical player in this transformation. You will be responsible for driving concurrent engineering (DFM/DFMA), supplier process readiness, industrialization, and engineering change implementation for steel components and assemblies across Nextpower’s global supply base.

The Manufacturing Engineer – Module Frames will lead initiatives to document and develop best practice solutions and new manufacturing technologies across the supplier footprint that includes, but not limited to, automation, inspection, operational excellence (lean thinking). This role partners directly with R&D/Design Engineering, Quality, Program Management, or Procurement to ensure new and existing designs are manufacturable, scalable, cost-effective, and reliable, and to support design release and change-control decisions through rigorous engineering analysis and factory validation, while ensuring a customer-centric approach to meet or exceed internal and external customer expectations.

Responsibilities

• Support the launch, commissioning and ramp up of new equipment at supplier locations, domestic and/or internationally.
• Participate in product development from concept through design release, providing manufacturing feasibility input and DFM/DFMA recommendations. Partner with suppliers to obtain and incorporate external DFM feedback and capability constraints
• Review engineering drawings, specifications, and design revisions; identify manufacturability risks and propose engineering solutions. Support structured design release gates by providing engineering recommendations based on manufacturability, process capability, cost drivers, and supplier readiness
• Lead and/or drive innovation in manufacturing technologies and technical readiness activities for complex roll forming of steel products while incorporating other technologies where applicable, such as stamping, casting, linear welding, laser cutting, machining, coating/finishing, assembly, testing, and/or automation
• Plan and execute prototype builds, supplier trials, and on-site validations; verify functional intent and key/critical dimensions through appropriate measurement and inspection methods
• Lead technical value engineering and cost-reduction initiatives across module frame products by identifying cost drivers and developing engineering solutions (design alternatives, process alternatives, tooling strategy changes, yield improvement, cycle-time reduction). Validate savings while maintaining product performance, reliability, safety, and manufacturability; document results and deploy best practices across regions and suppliers
• Define and validate manufacturing readiness deliverables, as applicable: process flows, manufacturing risk assessments, inspection approaches, work instructions, packaging requirements, and ramp-readiness checklists
• Conduct supplier factory readiness audits and support supplier ramp execution; identify constraints (capacity, tooling, capability, quality systems, asset management) and drive corrective action plans
• Identify and deploy manufacturing technologies and best practices across the supplier footprint, including automation and inspection equipment
• Define technical requirements for tooling/equipment; develop and execute FAT/SAT acceptance criteria and validation checklists; support installation, commissioning, and training with suppliers
• Serve as a Manufacturing Engineering reviewer/approver for engineering changes (ECR/DCO/ECO) in the company PLM system; drive controlled implementation at suppliers
• Provide rapid technical escalation support when supplier, manufacturing, or field issues negatively impact Nextpower customers; lead structured root-cause and corrective actions (8D, 5-Why, Pareto) and verify effectiveness
• Document best practices across the group and deploy standardized solutions across the supplier base
• Participate in NPI readiness reviews and cross-functional meetings as required to track technical readiness, prototype status, validation outcomes, and risk closure

Requirements

• Education & Experience:
• Bachelor’s degree in an Engineering discipline from an accredited institution with at least 10+ years of relevant experience in manufacturing engineering / industrialization for complex roll formed steel components and assemblies in an OEM or contract manufacturing environment
• Industrial, Mechanical, Manufacturing, Metallurgical or Chemical Engineering is preferred
• 10+ years minimum experience in design for manufacturing, steel manufacturing processes or steel machinery (leading CAPEX projects implementing machinery or equipment into factories)
• 5+ years minimum experience serving large OEM customers in renewable energy, automotive, consumer electronics, consumer goods, or industrial manufacturing (solar tracker experience a plus)
• Demonstrated experience delivering concurrent engineering outcomes: DFM/DFMA influence on design releases, supplier capability translation into design requirements, and factory validation
• Strong experience with roll forming complex steel shapes and fabrication processes (roll forming, stamping, welding, casting, laser cutting, machining, coating/finishing, assembly, automation). Experience with additional manufacturing processes is a plus
• Experience leading supplier-facing engineering activities including process readiness, tooling readiness, validation builds, and on-site troubleshooting
• Experience with engineering change management in a PLM system and the discipline to execute controlled implementation
• CAD collaboration capability for manufacturability reviews (SolidWorks or equivalent) and the ability to interpret engineering drawings and specifications
• Working knowledge of Lean Manufacturing / Six Sigma concepts and structured problem solving (8D, 5-Why, Pareto)
• Strategic mindset. Ability to bring clarity, structure, and actions to ambiguous plans and technical challenges
• Ability to influence others and negotiate solutions in critical timely decisions
• Experience working with global, cross-functional, and multicultural teams
• Excellent oral and written communication skills in English, including the ability to organize, conceptually interpret and clearly communicate material developed collaboratively via the input of multiple parties; translate complexity into actionable
• Demonstrated ability to manage large, complex change efforts and to drive results through the creative use of facts and quantitative data, as well as influence, persuasion, and relationship management
• Demonstrated ability to translate strategy to action; influence, negotiation, change mgt, and presentation
• Able to work flexible schedules occasionally to accommodate global work teams
• Travel requirements 75% (international and domestic)

Preferred

• SSGB, PMP, Lean Manufacturing, Journeyman, or other industry certifications
• Direct experience with domestic and offshore Tier 1 and Tier 2 suppliers
• Able to come up with new processes and bring rigor in the processes that are released

Why You’ll Love Working Here

Innovate with Purpose: Your work directly contributes to accelerating the global shift to renewable energy.

Global Impact: Collaborate with world-class engineers, suppliers, and partners across continents.

High-Growth Environment: Be part of a fast-moving, mission-driven team shaping the future of solar technology.

Empowered Culture: We value bold ideas, authentic collaboration, and a relentless drive for excellence.

At Nextpower, we are driving the global energy transition with an integrated clean energy technology platform that combines intelligent structural, electrical, and digital solutions for utility-scale power plants. Our comprehensive portfolio enables faster project delivery, higher performance, and greater reliability, helping our customers capture the full value of solar power. Our talented worldwide teams are redefining how solar power plants are designed, built, and operated every day with smart technology, data-driven insights, and advanced automation. Together, we’re building the foundation for the world’s next generation of clean energy infrastructure.

Nextpower is an equal opportunity employer. We celebrate diversity and are committed to creating an inclusive environment for all employees.

We are Nextpower