Senior Production Engineer - J0050976

Astemo Ltd.; Berea (KY); On-site; USD 110,000 - 160,000; Full time

Job summary

Astemo Ltd. is seeking a senior engineering leader to optimize manufacturing processes in a high-volume automotive setting. You will drive Lean Six Sigma improvements, oversee NPI activities, and mentor production engineers while collaborating with cross-functional teams to ensure operational excellence.

This role emphasizes automation, digital manufacturing practices, and strict adherence to quality and safety standards in a fast-paced, launch-intensive environment.

Qualifications

• Bachelor's degree in an engineering field required.
• 7+ years automotive manufacturing experience preferred.
• Experience with automated EV/HEV production is a plus.

Responsibilities

• Lead Lean and Six Sigma initiatives to improve OEE and throughput.
• Drive continuous improvement and automation in high-volume production.
• Coordinate NPI and APQP/PPAP activities with cross-functional teams.
• Ensure safety, quality, and regulatory compliance (IATF 16949, ISO 14001).
• Provide technical leadership to site production engineers and cross-functional teams.

Skills

Leadership

Project management

Cross-functional teamwork

Lean Six Sigma

Analytical thinking

Education

Bachelor’s degree in Electrical, Mechanical, Manufacturing, or Other Engineering

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)