Senior Engineer

Astemo Ltd.; Berea (KY); On-site; USD 95,000 - 125,000; Full time

Job summary

Astemo Ltd. seeks a leadership-minded engineer to optimize high-volume manufacturing, drive continuous improvement, and advance automation in a fast-paced, tech-forward environment.

You will lead NPI activities, APQP/PPAP, Run-at-Rate, and process capability studies while supporting PFMEA, control plans, and shop-floor readiness with strict adherence to IATF 16949 and ISO 14001 standards.

Qualifications

• Bachelor's degree in a engineering field (Electrical, Mechanical, Manufacturing) is required.
• 5–7 years of manufacturing experience.
• Automotive manufacturing experience and EV/HEV exposure preferred.

Responsibilities

• Lead Manufacturing Process Optimization & Continuous Improvement to boost OEE, throughput, and line performance.
• Support New Product Introduction (NPI) with APQP, PPAP, and Run-at-Rate activities.
• Collaborate with Corporate PE team on automation, robotics, vision systems, and AI deployment.
• Support PFMEA, Control Plans, and Standard Work Instructions for new products; validate equipment and processes.
• Ensure safety, quality, and regulatory compliance (IATF 16949, ISO 14001); drive root-cause analysis.

Skills

Leadership

Cross-functional teamwork

Project management

Data analysis

Continuous improvement

Automation

Vision systems

AI technologies

Safety awareness

Education

Bachelor's degree in Electrical Engineering

Bachelor's degree in Mechanical Engineering

Bachelor's degree in Manufacturing Engineering

Tools

APQP/PPAP knowledge

Job description

This position will provide leadership, technical expertise, and critical engineering role in optimizing manufacturing processes, supporting world-class quality with high-volume production, leading process innovation in a fast-paced, technology-driven environment. This position supports both current production and new program launches, with a strong focus on continuous improvement, automation, and advanced manufacturing techniques.

Key Responsibilities

Manufacturing Process Optimization & Continuous Improvement

• Lead improved line performance by driving OEE, throughput, equipment uptime/reliability, and cycle time improvements with Cross-Functional team.
• Analyze and interpret production data to identify and eliminate bottlenecks.
• Troubleshoot complex process &d equipment issues, implementing robust corrective actions.
• Support Digital Manufacturing initiatives (MES, Smart Factory Technologies)

New Product Introduction (NPI), Automation, & Advanced Engineering

• Lead collaboration with the Corporate PE team to support program launches through APQP, PPAP, and Run-at-Rate activities.
• Support Corporate PE team with development and optimization of manufacturing processes including automation, robotics, visions systems, and AI technology.
• Support PFMEA, Control Plans, and Standard Work Instruction development for new products.
• Support Corporate PE team with equipment validation, process capability studies, and pilot builds.
• Ensure manufacturing readiness for Start of Production (SOP).

Safety, Quality, & Compliance

• Promote Safety First culture & maintain industry leading safety performance
• Ensure compliance with IATF 16949, ISO 14001, & customer-specific requirements.
• Support root cause investigations using 8D, 5-Why, FTA, and Fishbone analysis.
• Implement error-proofing (poka-yoke) to reduce scrap, rework, & warranty risks.

PE Department & Cross-Functional Team (CFT) Leadership

• Provide supervisory support & technical leadership for other Site Production Engineers, as assigned by PE Department Management.
• Provide technical leadership for the Cross-Functional Team on the shop floor.
• Interface directly with OEM customers and key suppliers when required.

Required Qualifications

• Bachelor’s degree in Electrical, Mechanical, Manufacturing, or Other Engineering field required.
• 5-7 years experience in a manufacturing environment.

Experience (preferred)

• Automotive manufacturing experience, preferably Tier 1 supplier environment.
• Direct experience with automated (EV/HEV systems) production environments.

Knowledge, Skills, & Abilities (preferred)

• Strong leadership and project management capabilities
• Effective communication with cross-functional and global teams
• Ability to proactively identify safety risks/near misses & drive effective improvements
• Strong knowledge of AIAG standards for Automotive Manufacturing (ex. APQP, PPAP, Control Plans, PFMEA, Standard Work)
• Analytical and leadership skills to drive CFT problem solving activities through root cause determination & countermeasure implementation
• SPC and Process Capability analysis
• Ability to identify opportunities and implement Automation, Robotics, Vision Systems, AI technologies, MES Systems, Lean Manufacturing techniques, etc. to optimize processes
• Ability to thrive in a fast-paced, launch-intensive environment

Key Performance Indicators (KPIs)

• Safety Performance (OSHA Incident Rate-OIR) & Compliance
• Customer Concerns (Parts Per Million – PPM)
• Scrap and Defect Reduction (% of Sales $)
• Productivity (Efficiency, OEE – FTQ, Availability, & Performance %)
• Throughput improvement (Plan Attainment %, Jobs Per Hour – JPH)
• Successful product launches (on-time, in-budget, 0 PPM)