Sr. Manufacturing Engineer

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

We are a world leader in protective equipment, with a reputation for innovative design, high-performance quality and specialist materials expertise. Our two brands, Avon Protection and Team Wendy, supply our respiratory and head protection portfolio to customers across the globe from our manufacturing sites in theUKandNorth America. With over 900 talented people our shared purpose and core beliefs are to be #FIERCE about Protecting Lives. It's why we come to work - and it's what motivates us, every day, to do the best work we can.

Purpose of Position:

We are looking for a driven, creative, and analytical thinker with the main responsibility of ensuring continuous operation of ballistic helmet manufacturing Value Streams by leading our supporting engineers in assisting with identifying, troubleshooting, and resolving line stoppage issues. You will drive process stability and efficiency through root cause analysis and corrective actions To be successful as a Senior Manufacturing Engineer you should demonstrate a sound understanding of industrial processes and concepts, be able to work well in a team, and contribute to the overall goals of the team. Outstanding Senior Manufacturing Engineers are self-starters with an insatiable curiosity, a superb work ethic, and strong interpersonal skills. We are looking for a candidate that has a strong work ethic and ability to pivot across multiple projects and tasks in a high energy environment.

Job Title: Sr. Manufacturing Engineer Location: Cleveland, OH Business Unit: Team Wendy About Avon Technologies: We are a world leader in protective equipment, with a reputation for innovative design, high-performance quality and specialist materials expertise. Our two brands, Avon Protection and Team Wendy, supply our respiratory and head protection portfolio to customers across the globe from our manufacturing sites in theUKandNorth America. With over 900 talented people our shared purpose and core beliefs are to be #FIERCE about Protecting Lives. It's why we come to work - and it's what motivates us, every day, to do the best work we can.

Essential Duties and/or Functions:

• Lead advanced troubleshooting and resolution of complex manufacturing issues impacting production efficiency and quality.
• Drive strategic process improvements using Lean, the Avon Strengthen System, and other advanced methodologies to optimize throughput and reduce waste.
• Develop and implement long-term manufacturing strategies aligned with organizational goals and cost targets.
• Oversee design and validation of sophisticated tooling, fixtures, and automation systems to support high-volume, low-defect production. Manage cross-functional projects involving R&D, quality assurance, and operations to ensure seamless product introduction and process integration.
• Establish and maintain robust process control systems, including statistical process control (SPC) and failure mode analysis. Mentor and provide technical guidance to Manufacturing Engineers and production teams to build organizational capability. Evaluate and select advanced manufacturing technologies and equipment to improve scalability and competitiveness.
• Collaborate with suppliers and vendors on technical specifications, qualification, and continuous improvement of materials and components. Ensure compliance with regulatory, safety, and quality standards across all manufacturing operations.
• Develop and maintain comprehensive documentation for processes, tooling, and equipment, ensuring adherence to best practices. Lead cost-reduction initiatives through design-for-manufacturability (DFM) and process optimization.
• Serve as technical authority for manufacturing during new product development, ensuring readiness for full-scale production.

Required/Minimum Qualifications:

• Bachelor's degree in Manufacturing Engineering, Mechanical Engineering, or a related technical discipline.
• 7+ years of experience in a manufacturing environment, with demonstrated 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 skills with experience driving cross-functional initiatives.
• 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 and provide technical leadership within the organization.
• Demonstrated capability to work independently and manage multiple priorities in a fast-paced environment.
• Proven leadership of cross-functional CI initiatives and major capital projects (> $250k), from business case through commissioning.
• Expert-level design-for-manufacturability/assembly (DFM/DFA), GD&T, tolerance stack, and process capability (Cp/Cpk) with robust SPC/MSA deployment.
• Deep experience with control plans, PFMEA, and structured problem solving (5-Why, fishbone) applied in high-mix, safety-critical manufacturing.
• Controls familiarity sufficient to partner with maintenance/controls engineering: Allen-Bradley PLCs, HMIs, industrial sensors, and basic ladder logic review.

Desired Qualifications

• Proven leadership of cross-functional CI initiatives and major capital projects (> $250k). Expert-level design-for-manufacturability/assembly (DFM/DFA).
• Composites and adhesives process knowledge relevant to composite ballistic helmets.
• ERP/MES integration experience for routings, BOMs, serialization/traceability, and shop-floor data capture; IFS and Tulip familiarity preferred. Advanced statistic and data tool knowledge: DOE (screening/optimization), reliability analysis, and proficiency with data analysis/reporting. Regulatory/quality fluency: ISO 9001/AS9100 systems, ITAR/EAR, document control/change management, and QCP alignment for configuration-controlled products.
• Exceptional technical writing (work instructions, troubleshooting guides) and executive-ready communication for status, risk, and decisions. Mentorship track record: developing engineers and technicians; setting engineering standards consistent with senior-level role behaviors

What We Offer:

• Flexible Schedule
• Competitive Compensation Package
• Medical, Dental, Vision Insurance
• 401k Matching
• Tuition Reimbursement
• Learning and Development Initiatives

Internal Relationships: Maintenance Team; Operations/Production Department; Facilities Management; Safety and Compliance Department; Engineering and Technical Support; Human Resources (HR); Procurement and Supply Chain; Finance and Budgeting; Senior Management. External Relationships: Vendors and Suppliers; Contractors; Regulatory Agencies; Industry Associations; Emergency Services; Consultants; Customers or Clients; Local Community.

This job description is not intended, and should not be construed, to be an all-inclusive list of all responsibilities, skills, efforts or working conditions associated with this job. While this job description is intended to be an accurate reflection of the job requirements, management reserved the right to modify, add or remove duties from particular jobs and to assign other duties as necessary.

Responsibilities of this position may include direct and/or indirect physical or logical access to information, systems, technologies subjected to the regulations/compliance with U.S. Export Control Laws.

U.S. Export Control laws and U.S. Government Department of Defense contracts and sub-contracts impose certain restrictions on companies and their ability to share export-controlled and other technology and services with certain "non-U.S. persons" (persons who are not U.S. citizens or nationals, lawful permanent residents of the U.S., refugees, "Temporary Residents" (granted Amnesty or Special Agricultural Worker provisions), or persons granted asylum (but excluding persons in nonimmigrant status such as H-1B, L-1, F-1, etc.) or non-U.S. citizens. To comply with these laws, and in conjunction with the review of candidates for those positions within Avon that may present access to export controlled technical data, Avon must assess employees' U.S. person status, as well as citizenship(s). The questions asked in this application are intended to assess this and will be used for evaluation purposes only. Failure to provide the necessary information in this regard will result in our inability to consider you further for this particular position. The decision whether or not to file or pursue an export license application is at Avon's sole election.

Must be legally authorized to work in country of employment without a sponsorship for employment visa status (e.e. H1B status).

The anticipated salary range for candidates who will work in Cleveland, OH is $95,000 to $110,000 annually. The final salary offered to a successful candidate will be dependent on several factors that may include but are not limited to the type and years of experience within the job, type and years of experience within the industry, education, etc.

EOE AA M/F/Vet/Disability