Sr Advanced Manufacturing Engineer - Assembly

Harley-Davidson Motor Company; Wauwatosa (WI); On-site; USD 93,400 - 145,000; Full time

Benefits offered by this job

Health insurance

401k program

Onsite fitness centers

Employee stores

Employee discounts

Job summary

Harley-Davidson Motor Company is seeking a Sr Advanced Manufacturing Engineer to lead assembly process development and tooling delivery at the Wauwatosa location. The role partners with Product Development, Quality, Supply Chain, and Plant Operations to deliver innovative assembly solutions from concept through production.

You will own PFMEA/Control Plans, drive DFA, and manage capital budgets, tooling, and supplier engagement.

Qualifications

• Requires a bachelor’s degree in engineering or related field.
• Minimum 5 years in manufacturing, assembly engineering or launch roles.
• Experience with DFA, tooling and capital projects is preferred.

Responsibilities

• Lead assembly process development from concept to implementation.
• Influence DFA with early product development collaboration.
• Define and implement assembly tooling, fixtures, and equipment.
• Support make/buy analysis and supplier tooling decisions with should-cost input.
• Lead PFMEA/Control Plans and ensure documentation accuracy.
• Manage project plans, budgets, and plant readiness milestones.
• Drive continuous improvement using CI and 5S methodologies.

Skills

Leadership

Cross-functional collaboration

Problem solving

Analytical thinking

Project management

Education

Bachelor's degree in Engineering

High School Diploma or Equivalent

Tools

PFMEA

Control Plans

Job description

Company Overview

In 1903, out of a small shed in Milwaukee, Wisconsin, four young men lit a cultural wildfire that would grow and spread across geographies and generations. Their innovation and imagination for what was possible on two wheels sparked a transportation revolution that would make Harley-Davidson the most recognizable motorcycle brand in the world. Today, we continue to define motorcycle culture, evoking soul‑stirring emotion reflected in every product and experience we deliver - like we have for well over a century and will for generations to come. Are you ready to ride with us?

Location & Center

The Harley-Davidson Motor Company Product Development Center (PDC) located in Wauwatosa, WI is home to the mantra - You dream it. We build it. Join our team as a Sr Advanced Manufacturing Engineer - Assembly.

Job Summary

The Senior Engineer - Advanced Manufacturing (Assembly) plays a key role in the manufacturing process development and implementation and is responsible for supporting and delivering the Life Cycle Plan from concept to production at our various manufacturing plants. This role works collaboratively with Product Development, Quality, Supply Chain, and Plant Operations to yield innovative products and processes. The role requires strong leadership through expertise, decision influence, and cross‑functional collaboration. Impacts opportunities to influence design for assembly and solves complex problems with development of integrated manufacturing systems, standardized processes and templates, risk assessment and mitigation, and after‑action reviews.

Responsibilities

Assembly Engineering, Tooling & Launch Support

• Lead assembly process development and solve complex problems involving medium to large scale projects from concept to development, through capital funding planning and approval, and ultimately through successful implementation using analytical thought, exercising judgment and identifying innovative solutions.
• Influence Design for Assembly (DFA) by engaging early with Product Development and incorporating manufacturing and plant lessons learned.
• Define, design, and implement assembly tooling, fixtures, gauges, and equipment, including capital planning, supplier sourcing, and installation.
• Support make/buy analysis to inform product and process decisions, including evaluation of in‑house vs. supplier assembly and tooling solutions with should cost analysis.
• Perform supplier technical assessments and implement supplier technical development plans.
• Define, validate, and approve torque strategies, fastening methods, and error‑proofing concepts.
• Serve as the technical escalation point for complex assembly, tooling, equipment, and quality issues during builds and start of production.
• Support build events (VB, PB, Pre‑Pod) ensuring station readiness, documentation accuracy, and execution.

iPPAP / PPAP, PFMEA & Control Plan Ownership

• Serve as the Advanced Manufacturing lead or core contributor for iPPAP and PPAP readiness for assembly processes.
• Lead or support development and maintenance of PFMEAs and Control Plans for assembly processes, ensuring alignment with plant execution and quality requirements.
• Ensure completeness and accuracy of manufacturing deliverables including process flows, SWS, BOMs, tooling lists, PFMEAs, and Control Plans.
• Lead validation of tooling capability, fixture readiness, equipment capability, torque tool MSA, and capability studies.
• Identify and close manufacturing readiness gaps prior to PB, Pre‑Pod, and SOP milestones.
• Support quality audits, launch holds, and post‑SOP issues related to new product iPPAP/PPAP compliance and process adherence.

Project Management & Execution

• Apply project management tools and techniques to manage scope, cost, timing, and risk for assembly and tooling deliverables.
• Develop and manage capital budgets, cost estimates, and spend tracking for tooling, equipment, and assembly solutions.
• Maintain detailed project plans and ensure alignment to NPD milestones and plant readiness targets.

Continuous Improvement

• Use Manufacturing principles including CI, Six Sigma, and 5S.
• Drive structured problem solving using 8D and continuous improvement methodologies.
• Ensure production feedback is used to drive ongoing product and process improvements.

Optional / Value‑Add Capabilities

• As program needs require, the Senior Engineer may support digital manufacturing activities such as virtual DFA reviews, ergonomic assessments, or virtual builds. Digital manufacturing experience is a value‑add, not a prerequisite.

Education

High School Diploma or Equivalent Required

• Bachelor's degree in Engineering preferred (Mechanical, Industrial, Manufacturing, or related field).

Experience

This position typically requires a minimum of 5 years of related experience in manufacturing, assembly engineering, tooling, or launch‑related roles. In addition, the successful candidate will have demonstrated the following:

• Demonstrated experience in New Product Development, launch support, and cross‑functional problem solving.
• Experience supporting make/buy analysis, tooling and equipment implementation, and iPPAP/PPAP processes.
• Working knowledge of PFMEA, Control Plans, and manufacturing quality systems.
• Strong analytical, communication, project management, and decision‑making skills.
• Demonstrated ability to work effectively within and / or lead a group or team providing guidance to members.

The pay range shown represents the national average pay range for this role. Your pay may be more or less than the stated range and is dependent on your geographic location and level of experience.

We offer an inclusive compensation package for all full‑time salaried employees including, but not limited to, annual bonus programs, health insurance benefits, a 401k program, onsite fitness centers and employee stores, employee discounts on products and accessories, and more. Learn more about Harley-Davidson here.

Applicants must be currently authorized to work in the United States.

Direct Reports: No

Travel Required: 10 - 25%

Pay Range: $93,400 - $145,000

Visa Sponsorship: This position is not eligible for visa sponsorship or visa transfer

Relocation: This position is eligible for domestic relocation assistance (within posted country)