Senior Manufacturing Engineer - Lean & Automation

Avon Technologies plc; Cleveland (OH); On-site; USD 95,000 - 110,000; Full time

Benefits offered by this job

Flexible Schedule

Medical, Dental, Vision Insurance

401k Matching

Tuition Reimbursement

Learning and Development Initiatives

Job summary

Avon Technologies plc in Cleveland, OH, seeks a Sr. Manufacturing Engineer in the Team Wendy unit to ensure continuous operation of ballistic helmet manufacturing. You will lead engineers to troubleshoot line stoppages, drive process stability, and implement corrective actions through root cause analysis.

The role requires 7+ years in manufacturing, strong Lean, DFMA/DFM, SPC, PFMEA, and cross-functional collaboration with R&D, QA, and operations to scale production efficiently.

Qualifications

• Bachelor's degree in Manufacturing Engineering, Mechanical Engineering, or related technical discipline.
• 7+ years in manufacturing with leadership in process improvement and technical problem-solving.
• Proven ability to lead complex root cause analysis and implement sustainable corrective actions.
• Advanced knowledge of Lean manufacturing principles, methodologies, and continuous improvement tools; strong project management.
• Expertise in tooling design, automation, and process validation for high-volume production (poka-yoke, vision systems, error-proofing).
• Excellent communication skills for influencing stakeholders and leading technical discussions.
• Strong technical writing and documentation skills for developing standards, procedures, and reports; ability to mentor junior engineers.
• Ability to manage multiple priorities in a fast-paced environment.
• Proven leadership of cross-functional CI initiatives and major capital projects (> $250k).
• DFM/DFA, GD&T, tolerance stack, and Cp/Cpk with SPC/MSA deployment.
• Deep experience with control plans, PFMEA, and structured problem solving (5-Why, fishbone).
• Familiarity with Allen-Bradley PLCs, HMIs, industrial sensors, and basic ladder logic.

Responsibilities

• Lead advanced troubleshooting and resolution of complex manufacturing issues impacting production efficiency and quality.
• Drive strategic process improvements using Lean, Avon Strengthen System, and other methodologies to optimize throughput and reduce waste.
• Develop and implement long-term manufacturing strategies aligned with cost targets.
• Oversee design and validation of tooling, fixtures, and automation to support high-volume production; manage cross-functional projects.
• Establish and maintain robust SPC and PFMEA; mentor manufacturing engineers and production teams.
• Collaborate with suppliers on specifications, qualification, and continuous improvement; ensure safety and quality standards.
• Develop and maintain comprehensive process documentation and lead cost-reduction through DFM and process optimization.
• Serve as technical authority for manufacturing during new product development and scale-up.

Skills

Lean manufacturing

Poka-yoke

DFM/DFA

GD&T

Cp/Cpk

SPC

Root cause analysis

Project management

Automation design

Allen-Bradley PLCs

Cross-functional leadership

Education

Bachelor's degree in Manufacturing Engineering

Bachelor's degree in Mechanical Engineering

Tools

IFS

Tulip

DOE

Job description

Avon Technologies plc in Cleveland, OH, seeks a Sr. Manufacturing Engineer in the Team Wendy unit to ensure continuous operation of ballistic helmet manufacturing. You will lead engineers to troubleshoot line stoppages, drive process stability, and implement corrective actions through root cause analysis.

The role requires 7+ years in manufacturing, strong Lean, DFMA/DFM, SPC, PFMEA, and cross-functional collaboration with R&D, QA, and operations to scale production efficiently.