Senior Manufacturing Engineer

LEMO GROUP; Rohnert Park (CA); On-site; USD 90,000 - 130,000; Full time

Job summary

LEMO GROUP in California seeks a hands-on manufacturing engineer responsible for planning, organizing, and executing fabrication of complex cable assemblies using injection molding and automated testing. You will drive improvements to current and future molding processes and controls to meet customer specs and quality standards.

This role requires five years of mold making/injection molding experience, strong project management, and the ability to translate designs into clear shop-floor

Qualifications

• Bachelor’s degree in engineering or equivalent experience.
• Minimum five years in mold making and injection molding.
• Experience with soldering, crimping, and post-termination inspection.
• Able to interpret electrical, mechanical, and quality requirements.
• Strong project organization and time management.
• Excellent verbal and written communication.
• Proficient in 3D CAD (Inventor or SolidWorks).
• Hands-on with fixtures and tooling.

Responsibilities

• Develops cost-effective molding, jigs & fixtures, processes, and methods per specs.
• Identify KPIs and monitor performance using basic SPC.
• Document processes with flow charts, capacity studies, and time-motion analyses.
• Translate complex designs into clear assembly instructions for shop floor.
• Review customer specs for Build to Custom Design projects and provide feedback.
• Develop manufacturing concepts to simplify processes and reduce costs.
• Oversee equipment process validations (PPAP, DQ/IQ/OQ/PQ).
• Perform PFMEA analyses and mitigation plans; keep PFMEA current.
• Define all process steps and equipment for fabrication and qualification.
• Propose corrective measures using Six Sigma, 8D, RCCA methods.
• Develop and test new DFM methods; apply lean, Kaizen, Six Sigma ideas.
• Assist in writing/editing procedures to support best practices.
• Collaborate with Design Engineering on injection mold designs for medical/defense/commercial.
• Provide leadership and training to junior manufacturing associates.
• Other duties as required.

Skills

Project management

Time management

Verbal communication

Written communication

Customer requirement interpretation

Attention to detail

Education

Bachelor’s degree in engineering (BSME/BSIE) or significant related experience

Tools

3D CAD (Inventor/SolidWorks)

Injection molding equipment

CNC machines

CFD / Mold Flow software

Job description

Assumes full technical responsibility for planning, organizing, and executing the fabrication of complex cable assemblies, utilizing injection molding and automated testing. Recommends and implements improvements to current & future injection molding processes, methods, and controls.

DUTIES and RESPONSIBILITIES

• Develops cost-effective injection molding, jig & fixtures, processes, and methods, in accordance with customer specifications and quality standards
• Identify key process indicators (KPIs) and collect data into meaningful metrics on a routine basis. Use basic SPC to monitor performance and suggest areas of improvement
• Create and maintain required documentation for all manufacturing processes, including flow charts, capacity and utilization studies, time and motion studies, standard workflow, cycle time analysis, and line balancing.
• Coordinates interpretation of complex technical designs into clear and understandable assembly instructions for execution by shop floor personnel
• Review customer specifications for Build to Custom Design projects, provide feedback to Project Managers and customers as required
• Design and develop complex manufacturing concepts to simplify and improve processes and ensure best practices. Develops manufacturing cost analysis of cable products and ensures workflows are optimized over time to achieve cost targets.
• Responsible for all activities relating equipment process validations (PPAP), DQ, IQ, OQ, PQ
• Perform PFMEA Risk Analyses when required (ISO 13485 opportunities), develop plans to mitigate risk, and keep PFMEA alive throughout product life
• Define all manufacturing process steps and equipment required for the complete fabrication and qualification of a cable assembly
• Propose and implement corrective measures to address customer complaints using Six Sigma, 8D, and RCCA forms and methods
• Develop and test new DFM methods to support innovation and improvements utilizing lean manufacturing, Kaizen, Six Sigma methodologies
• Assist in the writing and editing of manufacturing procedures and processes to support best practices
• Work with Design Engineering to support injection mold designs for medical, defense and commercial applications.
• Provide leadership, training, and guidance to junior manufacturing associates in the execution of everyday tasks
• Other duties as required

Required Qualifications

• Bachelor’s Degree in engineering preferred (BSME, BSIE), or significant related work experience
• Five (5) years minimum experience in the mold making and injection molding industry.
• Experience with soldering, and crimping technologies including post termination performance and inspection requirements
• Able to understand/interpret customers electrical, mechanical, and quality requirements
• Strong project organization and time management skills
• Excellent verbal and written communication and presentation skills
• Working knowledge and use of 3D CAD such as Inventor or SolidWorks
• Hands-on ability to work with small tools and develop fixtures and mechanical devices as manufacturing aids.

Additional Preferred Qualifications/Skills

• Knowledge of various plastic materials used in the injection molding process such as PEEK, POM, PTFE, FEP, VMQ, Rubber, Polyamide, Polyurethane, PA6.6, PPSU, PSU, etc.
• Knowledge of various platings and coatings such as electrolytic nickel, electroless nickel, nickel hardened gold, and electroless nickel immersion gold (ENIG)
• Knowledge of various adhesives and potting compounds for bonding and electrical isolation and protection
• Familiarity with CFD, Mold Flow software analysis and interpretation for injection molding
• Familiarity with IPC 610/620 standards, ISO 9001, 13485

PHYSICAL JOB DESCRIPTION

Typical Working Conditions:

• Office environment, Quality Laboratory, Engineering Lab, Cable, Connector, injection molding work areas

Equipment Used:

• Computer and office equipment and tools used in Cable Assembly and Connector Assembly departments
• May work on equipment including injection machine, injection molds, CNC machines, Lasers, test equipment, crimp applicators and presses, programmable prep equipment, automated dispensing equipment, etc.

Essential Physical Tasks:

• Sitting and/or standing for prolonged periods of time