Senior Manufacturing Engineer – Advanced Processes & Test

Heron Power Inc.; Scotts Valley (CA); On-site; USD 130,000 - 180,000; Full time

Job summary

Heron Power Inc. in Scotts Valley, CA seeks a Sr./Staff Manufacturing Engineer - Advanced Processes to design, test, and scale inline inspection and electrical test strategies for high-volume transformer assembly lines.

You will partner with design and external suppliers to land repeatable equipment lines, lead MSA and PFMEA efforts, and drive DoEs to optimize complex high-viscosity potting and dispense systems. This is a hands-on, collaborative role in a fast-paced startup.

Qualifications

• Bachelor’s degree in Manufacturing/Industrial/Mechanical/Electrical/Chemical Engineering.
• 7+ years of experience in high volume manufacturing with a focus on process engineering, inline inspection, production test or automation for electromechanical, power electronics, magnetics or battery products.
• Hands-on experience deploying automated non-destructive inspection (X-ray/Ct, ultrasonic, thermography or vision) to detect voids, delamination or bond-line defects in production.
• Experience developing and validating automated electrical test for high volume production.
• Experience with design, optimization and validation for high-viscosity potting and dispense systems including material supply, metering, mixing, vacuum potting and degassing strategies.
• Experience with surface preparation processes and quantitative surface quality measurement.
• Experience with ultrasonic, hot plate and/or IR welding of plastics, including process monitoring and weld validation.
• Proficiency in statistical analysis, SPC, Cp/Cpk studies, hypothesis testing and Minitab/JMP.
• Demonstrated ability to run DoE’s and optimize complex processes.
• Experience implementing PFMEA’s, control plans, process flow diagrams.
• Hands-on experience with automation, robotics, PLCs and vision systems.

Responsibilities

• Lead inline inspection, process monitoring and automated electrical test across the Transformer Assembly line.
• Develop high-speed automated inspection of potting assemblies for voids, delamination, and curing defects using X-ray/CT, ultrasonic, thermography and vision.
• Develop surface treatments with atmospheric plasma/corona, cleaning and adhesion prep with inline verification.
• Architect and deploy automated high-volume electrical test equipment with fixtures and noise control.
• Collaborate with manufacturing engineers on potting/dispense systems and high-speed plastic welding processes.
• Lead MSA, Gage R&R and test method validation for inspection and electrical tests.
• Apply PFMEA, control plans, SPC and structured problem solving to achieve world-class process capability.
• Support automation integration with robots, conveyors and inline QA.

Skills

First principles thinking

Hands-on

Process engineering

Inline inspection

Electrical test development

Statistical analysis

DoE optimization

PFMEA & control plans

Automation & robotics

Vision systems

Education

Bachelor’s degree in engineering

Tools

Minitab

JMP

Job description

Heron Power Inc. in Scotts Valley, CA seeks a Sr./Staff Manufacturing Engineer - Advanced Processes to design, test, and scale inline inspection and electrical test strategies for high-volume transformer assembly lines.

You will partner with design and external suppliers to land repeatable equipment lines, lead MSA and PFMEA efforts, and drive DoEs to optimize complex high-viscosity potting and dispense systems. This is a hands-on, collaborative role in a fast-paced startup.