Prototyping Manager

Forgent Power Solutions, Inc.; Waco (TX); On-site; USD 120,000 - 180,000; Full time

Job summary

Forgent Power Solutions, Inc. is seeking a Prototyping Manager to lead the development and initial build of new products through the prototype phase into early production. You will oversee hands-on assembly, document issues, and partner with design engineering to apply DFM/DFA principles.

The role requires a strong manufacturing and quality background, leadership experience, and a track record of driving design for manufacturability into scalable production in a fast-growing environment.

Qualifications

• Bachelor’s degree in Engineering, Manufacturing, Industrial Technology, or related field.
• 7+ years of experience in manufacturing, product development, or prototyping environments.
• 2+ years of leadership or team management experience.
• Experience with new product introduction (NPI) or prototype-to-production transitions.

Responsibilities

• Lead and manage all prototyping activities, including planning, execution, and review of initial product builds.
• Oversee hands-on assembly of prototype units, ensuring alignment with engineering intent and design specifications.
• Identify, document, and track build issues, including design gaps, manufacturability challenges, tooling constraints, and quality risks.
• Drive root cause analysis and coordinate resolution of prototype issues with engineering, quality, and supply chain teams.
• Establish and maintain robust documentation processes, including build logs, work instructions, deviation reports, and engineering change requests (ECRs).
• Partner closely with design engineering to ensure Design for Manufacturability (DFM) and Design for Assembly (DFA) principles are applied.
• Develop standardized processes to transition prototypes into pilot and full-scale production, reducing variability and rework.
• Lead continuous improvement initiatives focused on cycle time reduction, yield improvement, and cost optimization.
• Build and scale prototyping capabilities, including tools, fixtures, workflows, and team structure, to support company growth.
• Coordinate with supply chain to ensure timely availability of prototype materials and components, including alternates as needed.
• Provide regular status updates to leadership, highlighting risks, timelines, and readiness for production transition.
• Mentor and develop a team of technicians and engineers, fostering a culture of accountability, documentation, and operational excellence.

Skills

Leadership

Problem solving

Cross-functional collaboration

Process discipline

Ownership

Continuous improvement

DFM/DFA awareness

Education

Bachelor’s degree in Engineering, Manufacturing, Industrial Technology, or related field

Job description

We are seeking a highly skilled and execution-focused Prototyping Manager to lead the development and initial build of new products through the prototype phase and into early production. This role is responsible for overseeing the first builds of complex systems, identifying design and manufacturing issues, and driving resolutions to ensure scalable, repeatable production.

The Prototyping Manager will play a critical role in bridging engineering and manufacturing—ensuring that lessons learned during prototype builds are systematically captured, documented, and incorporated into design and process improvements. The ideal candidate thrives in a fast-paced, scaling environment and brings a strong foundation in manufacturing, quality, and cross-functional leadership.

Key Responsibilities:

• Lead and manage all prototyping activities, including planning, execution, and review of initial product builds.
• Oversee hands-on assembly of prototype units, ensuring alignment with engineering intent and design specifications.
• Identify, document, and track build issues, including design gaps, manufacturability challenges, tooling constraints, and quality risks.
• Drive root cause analysis and coordinate resolution of prototype issues with engineering, quality, and supply chain teams.
• Establish and maintain robust documentation processes, including build logs, work instructions, deviation reports, and engineering change requests (ECRs).
• Partner closely with design engineering to ensure Design for Manufacturability (DFM) and Design for Assembly (DFA) principles are applied.
• Develop standardized processes to transition prototypes into pilot and full-scale production, reducing variability and rework.
• Lead continuous improvement initiatives focused on cycle time reduction, yield improvement, and cost optimization.
• Build and scale prototyping capabilities, including tools, fixtures, workflows, and team structure, to support company growth.
• Coordinate with supply chain to ensure timely availability of prototype materials and components, including alternates as needed.
• Provide regular status updates to leadership, highlighting risks, timelines, and readiness for production transition.
• Mentor and develop a team of technicians and engineers, fostering a culture of accountability, documentation, and operational excellence.

Qualifications

Required:

• Bachelor’s degree in Engineering, Manufacturing, Industrial Technology, or related field.
• 7+ years of experience in manufacturing, product development, or prototyping environments.
• 2+ years of leadership or team management experience.
• Demonstrated experience with new product introduction (NPI) or prototype-to-production transitions.
• Strong knowledge of manufacturing processes, assembly methods, and production workflows.
• Experience with issue tracking, root cause analysis, and corrective action methodologies.

Preferred:

• Experience in Transformer manufacturing
• Familiarity with Lean manufacturing, Six Sigma, or continuous improvement methodologies.
• Experience working in a scaling or high-growth organization.
• Knowledge of PLM systems, ERP systems, and engineering change management processes.
• Exposure to regulated or quality-driven environments (ISO, UL, etc.).

Skills and Competencies:

• Strong leadership and team-building skills with a hands-on, execution-oriented mindset.
• Exceptional problem-solving abilities with attention to detail and process discipline.
• Ability to translate prototype learnings into scalable manufacturing solutions.
• Effective cross-functional collaboration and communication skills.
• High sense of ownership and accountability in fast-paced, ambiguous environments.
• Strong organizational skills with ability to manage multiple builds and priorities simultaneously.
• Continuous improvement mindset with focus on operational efficiency and quality.

Forgent Power Solutions, Inc. All rights reserved.