Onsite Senior Manufacturing Process Engineer — Lean & NPI

Mainspring Energy; Menlo Park (CA); On-site; USD 120,000 - 190,000; Full time

Benefits offered by this job

Stock options

Benefits

Job summary

Mainspring Energy, a leader in fuel-flexible, low‑emissions local power, seeks a Senior/Staff Manufacturing Process Engineer to bridge product development and scalable production at its Menlo Park site. You’ll own process development, validation, and lifecycle improvements for high‑volume assembly, partnering with Mechanical, Electrical, Quality and Supply Chain teams.

The role emphasizes data‑driven problem solving, PFMEA, DOE, and Lean manufacturing to reduce risk and deliver repeatable, safe

Qualifications

• 7–10+ years of manufacturing/process engineering for complex electromechanical products.
• Expertise in PFMEA, Control Plans, Process Flow Diagrams, DOE, SPC, 8D, Cpk and GR&R.
• Experience scaling manufacturing processes and supporting NPI from prototype to production.
• Experience in assembly equipment, fixtures, gauges, and automation.
• Strong Lean, Six Sigma, Kaizen, line balancing, Yamazumi, time studies, and capacity modeling.
• Proven cross-functional leadership and data-driven decision making.
• Experience in fast-paced NPI environments with evolving designs.

Responsibilities

• Develop, validate, and optimize processes from prototype to high-volume production.
• Lead PFMEA workshops, DOE studies, capability analyses, and GR&R.
• Drive risk mitigation with Design Eng., Quality, and Operations.
• Establish manufacturing readiness, validation strategies, and quality gates.
• Collaborate on line balancing, cycle times, and resource utilization.
• Lead root-cause investigations and improve first-pass yield and OEE.
• Support factory layout, capacity planning, and new factory launches.

Skills

PFMEA

DOE

Cpk

GR&R

Lean Manufacturing

Six Sigma

Kaizen

Yamazumi charts

Time studies

Cross-functional leadership

Tools

Assembly equipment design

Fixtures and gauges

Automation systems

Job description

Mainspring Energy, a leader in fuel-flexible, low‑emissions local power, seeks a Senior/Staff Manufacturing Process Engineer to bridge product development and scalable production at its Menlo Park site. You’ll own process development, validation, and lifecycle improvements for high‑volume assembly, partnering with Mechanical, Electrical, Quality and Supply Chain teams.

The role emphasizes data‑driven problem solving, PFMEA, DOE, and Lean manufacturing to reduce risk and deliver repeatable, safe