R&D Manufacturing Engineer

Essex Solutions; Indiana (PA); On-site; USD 70,000 - 90,000; Full time

Job summary

Essex Solutions in the United States seeks a hands-on R&D engineer to lead design and optimization of magnet wire processing equipment. You will interface with global Innovation Team, apply engineering principles, and guide prototype development from concept through trials.

Requirements include a Bachelor’s in Mechanical or Chemical Engineering, 3+ years of experience, proficiency in SolidWorks, and experience with 3D printing. Travel 10–20% to Essex sites will be needed.

Qualifications

• Bachelor’s degree in Mechanical Engineering, Chemical Engineering or equivalent.
• 3+ years engineering experience.
• Proficient in SolidWorks or similar 3D modelling software.
• Experience with 3D printing or willingness to learn.
• Ability to assemble prototypes.
• Analytical skills: investigate problems, design experiments, document results.
• Hands-on experience with equipment operation and optimization.
• Experience creating tooling and standard work procedures.
• Willing to travel 10–20%, mostly day trips.
• Strong PC skills.

Responsibilities

• Interface with global Innovation Team to provide knowledge, skills and develop equipment which supports magnet wire products
• Apply sound engineering principles to produce state of the art magnet wire products with objective to improve quality, efficiency and cost
• Hands-on technical leadership of R&D process; plan and direct R&D production staff
• Develop, optimize, improve and lead training program for new hires
• Interpret internal specifications and lead design of process setup, tooling selection, and key parameters to produce critical customer samples
• Develop simulation models for tooling optimization
• Data collection, synthesis, and analysis from R&D production process; with emphasis on practical digital automation
• Assist with project management, planning and support, communicate milestones and critical paths
• Work with team members and other departments
• Provide technical support for new equipment evaluation; assist with the assembly, installation, startup, training, and product launch phases
• Operate and assist with the evaluation of prototype equipment; document performance and modifications
• Maintain records and files of versions and revisions
• Create and maintain operating instructions for all processes in R&D production process
• Promote safety, maintain a clean and well-organized workspace following 5S principles
• Work closely with equipment, process and material teams to ensure functional design and operation

Skills

SolidWorks

3D printing

Analytical skills

Hands-on

Prototyping

Travel 10–20%

Education

Bachelor’s degree in Mechanical or Chemical Engineering or equivalent

Tools

3D modelling software

Job description

• Interface with global Innovation Team to provide knowledge, skills and develop equipment which supports magnet wire products
• Apply sound engineering principles and methods to produce state of the art magnet wire products with objective to improve quality, efficiency and cost
• Hands-on technical leadership of R&D process. Technical project planning and direction to R&D production process staff.
• Develop, optimize, improve and lead training program for new hires working as R&D process staff.
• Interpret internal specifications (MWSS) and lead design of process setup, tooling selection, and key parameters to produce critical customer samples
• Develop simulation models for tooling optimization
• Responsible for data collection, synthesis, and analysis from R&D production process; with emphasis on practical digital automation.
• Assist with project management, planning and support, communicate project milestones and critical paths regularly to ensure functional and timely results
• Work and communicate well with team members and other departments
• Provide technical support for new equipment evaluation, assist with the assembly, installation, startup, training, and product launch phases
• Operate and assist with the evaluation of prototype equipment, document performance, and recommend modifications
• Maintain records and files of versions and revisions
• Creates and maintains operating instructions for all processes in R&D production process.
• Promote safety, maintain a clean and well-organized workspace following 5S principles
• Works closely with equipment, process and material teams to ensure functional design and operation

Essential Functions/Duties

• Interface with global Innovation Team to provide knowledge, skills and develop equipment which supports magnet wire products
• Apply sound engineering principles and methods to produce state of the art magnet wire products with objective to improve quality, efficiency and cost
• Hands-on technical leadership of R&D process. Technical project planning and direction to R&D production process staff.
• Develop, optimize, improve and lead training program for new hires working as R&D process staff.
• Interpret internal specifications (MWSS) and lead design of process setup, tooling selection, and key parameters to produce critical customer samples
• Develop simulation models for tooling optimization
• Responsible for data collection, synthesis, and analysis from R&D production process; with emphasis on practical digital automation.
• Assist with project management, planning and support, communicate project milestones and critical paths regularly to ensure functional and timely results
• Work and communicate well with team members and other departments
• Provide technical support for new equipment evaluation, assist with the assembly, installation, startup, training, and product launch phases
• Operate and assist with the evaluation of prototype equipment, document performance, and recommend modifications
• Maintain records and files of versions and revisions
• Creates and maintains operating instructions for all processes in R&D production process.
• Promote safety, maintain a clean and well-organized workspace following 5S principles
• Works closely with equipment, process and material teams to ensure functional design and operation

REQUIRED Knowledge/skills/abilities And Other Minimum Qualifications

• Bachelor’s degree in Mechanical Engineering, Chemical Engineering or equivalent.
• 3+ years previous engineering experience required.
• Confident and experienced in using Solidworks or comparable 3D modelling software.
• Experience with 3D printing or strong willingness to learn
• Ability to mechanically assemble prototypes
• Possess demonstrated ability with analytical skills: methodically investigate problems, organize logical experimental trials, document data, and present results.
• Possess “hands‑on” experience with equipment operation and optimization.
• Practical experience sufficient to create and modify tooling for sample production, relying on practical mathematics proficiency and engineering comprehension
• Possess ability to document and create standard work procedures, instructions, BOMs and other documentation.
• Strong PC skills required
• Willingness and ability to travel 10 to 20%, mostly day trips to other Essex sites, occasional overnight

Additional Qualifications

• Highly developed written and oral communication
• Experience with FEA/CFD preferred
• Experience with solution polymer coating processes.
• Experience with implementing automated statistical process control (SPC) tools for reporting and analysis; eg. Ignition, JMP, Minitab