Senior Production Engineer

Astemo; Kentucky; On-site; USD 90,000 - 120,000; Full time

Job summary

Astemo Americas, Inc. seeks an experienced Manufacturing Process Engineer to lead process optimization and continuous improvement for high-volume production.

You will drive lean manufacturing, Six Sigma initiatives, and automation projects in collaboration with global teams. You will support New Product Introductions, APQP/PPAP, Run-at-Rate activities, and Digital Manufacturing initiatives, ensuring SOP readiness and robust PCAs.

Qualifications

• Bachelor's degree in Engineering required.
• 7+ years in automotive manufacturing, preferably Tier 1 supplier environment.
• Direct experience with automated (EV/HEV) production environments.
• Strong leadership and project management capabilities.
• Effective communication with cross-functional and global teams.

Responsibilities

• Lead Lean Manufacturing & Six Sigma initiatives (Kaizen, 5S, VSM).
• Analyze production data to identify bottlenecks and improve line performance.
• Troubleshoot process and equipment issues and implement corrective actions.
• Support Digital Manufacturing initiatives (MES, Smart Factory Technologies).
• Lead NPI, automation, and advanced engineering activities with the Corporate PE team.
• Ensure manufacturing readiness for Start of Production (SOP).
• Promote safety culture and ensure compliance with IATF 16949, ISO 14001, and customer requirements.

Skills

Leadership

Project management

Cross-functional

AIAG standards

Lean manufacturing

Process optimization

Data analysis

Automation

AI tech

Education

Bachelor's degree in Engineering

Tools

MES systems

Robotics

Vision systems

AI technology

Job description

Company Name:

ASTEMO AMERICAS, INC.

Job Family:

Manufacturing & Operations

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 Lean Manufacturing & Six Sigma Initiatives (Kaizen, 5S, VSM).

• 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.

Qualifications

Education

• Bachelor's degree in Electrical, Mechanical, Manufacturing, or Other Engineering field required.

Experience (preferred)

• 7+ years in automotive manufacturing, 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)

Equal Opportunity Employer (EOE) – Qualified applicants will receive consideration without regard to their race, color, religion, sex, sexual orientation, gender, identity, disability, protected veteran status and national origin.

At Astemo, we're challenging the status quo with the power of diversity, inclusion, and collaboration. Our goal is to build an inclusive work environment that celebrates the differences of our employees. We want to ensure that every employee feels valued, respected and empowered. We don't just accept difference - we celebrate it, we support it, and we thrive on it for the benefit of our employees, our products, and our community. Astemo is proud to be an equal opportunity employer.