Senior Manufacturing Engineer

Insight Global; Fairview (NC); On-site; USD 90,000 - 130,000; Full time

Job summary

Insight Global is seeking a Senior Manufacturing Engineer to drive new product introduction, develop manufacturing processes, and optimize production for fiber optic assemblies. You will partner across Product Development, Operations and Quality to ensure cost-efficient, high-quality processes that meet safety and ergonomic standards.

You will lead NPD deliverables, perform PFMEAs, and use Lean, DMAIC and DOE methods to improve line layouts and equipment, while supporting CAPEX ROI and

Qualifications

• Experience in new product introduction manufacturing.
• Ability to design and deploy manufacturing processes into production.
• Familiarity with process control and quality alignment.

Responsibilities

• New Product & Process Development: Execute NPD phase-gate deliverables, conduct PFMEAs, support capability studies and cost estimates.
• Production Optimization: design and deploy equipment, improve layouts, apply Lean tools, ROI analyses for CAPEX.
• Manufacturing Support: maintain MIs, routings and specs for NPI, perform data collection and statistical analyses, apply DOE methods, ensure process capability with product specs.
• Serve as SME for fiber optic manufacturing processes across global operations.

Skills

NPI Manufacturing

Machine/Process design

Lean Manufacturing

DMAIC

5 Whys

8D problem solving

Education

Bachelor's degree in Mechanical / Electrical / Manufacturing Engineering

Job description

As a Senior Manufacturing Engineer, you will play a pivotal role in launching new products, developing, and implementing manufacturing technologies, and driving continuous improvement across operations. You’ll collaborate with Product Development, Operations, Quality, and other cross-functional teams to develop processes that support innovative new products while optimizing production, enhancing cost efficiency, and maintaining a commitment to quality and safety standards.

New Product & Process Development

• Execute deliverables for the NPD Phase Gate process.
• Conduct PFMEAs and implement high-risk mitigation strategies.
• Leverage ME tools to support development and qualification of manufacturing processes (e.g., capability studies, sample builds, FAIs).
• Collaborate on cost estimation for new product concepts.
• Ensure new process and equipment compliance with the safety and ergonomic policies.

Production Optimization

• Design, develop, and deploy equipment, tooling, and fixtures for fiber optic assemblies.
• Analyze and improve line layouts (material flow, ergonomics, waste reduction).
• Use Lean Manufacturing tools to reduce cost, improve quality, and increase throughput.
• Lead and support capital expenditure (CER) processes including justification and ROI analysis.
• Support root cause analysis using DMAIC, 5 Whys, 8D, and other problem-solving tools.

Manufacturing Support

• Sustain and improve current manufacturing processes with a focus on fiber optic assemblies.
• Create and maintain manufacturing instructions, routings, and specifications for new product introduction.
• Support data collection and perform statistical analysis to ensure process control.
• Utilize statistical and DOE methods to develop and optimize new manufacturing processes.
• Work closely with quality teams to define process limits and manage material specs, aligning process capabilities with product requirements.
• Serve as a subject matter expert for fiber optic manufacturing processes across the global operations footprint.

Must Haves:

• 5+ years' experience in relevant engineering experience
• Bachelor's degree mechanical, electrical or manufacturing engineering
• Experience with NPI Manufacturing
• Experience with machine/process design and deployment into production