Staff Engineer, Manufacturing - (req73043)

Sterling Kohler; Bristol Township, Northern (Bucks County, KY); Hybrid; USD 104,000 - 160,000; Full time

Job summary

Kohler Co. is seeking a Staff Engineer, Manufacturing in Bristol, PA. This onsite role leads new product introductions and capabilities, coordinating across engineering, manufacturing, and supply chain to ensure on-time launches and quality objectives.

You will design processes, oversee equipment procurement, define SOPs, training, and validation plans. Strong collaboration and problem-solving skills are essential for continuous improvement initiatives.

Qualifications

• Bachelor’s degree in engineering from ABET accredited program.
• Minimum of 6 years engineering or related experience within a production assembly environment; automation experience preferred.
• Experience with metal/glass fabrication processes and tooling improvements is a plus.
• SolidWorks proficiency is a plus; Six Sigma/Lean training preferred.

Responsibilities

• Lead NPI and new manufacturing capabilities for the Bristol facility, coordinating across functions to launch on time.
• Provide input on design for manufacture, process capabilities, and make vs. buy analyses.
• Lead PFMEA during product launches and develop action plans to reduce risk.
• Create process routings, costings, and PCI SME support for new products.
• Develop cell layouts, SOPs, and training materials for new launches and capabilities.
• Conduct post-launch analysis to identify process and design improvements.
• Drive continuous improvement using Kohler Operating System principles.

Skills

Six Sigma / Lean Manufacturing

Project management

Cross-functional collaboration

Problem solving

Education

ABET accredited engineering program

Tools

SolidWorks

Automation integration

Job description

Staff Engineer, Manufacturing

Work Mode:Onsite

Location

Onsite – Bristol, PA

Opportunity

Responsible for leading New Product Introduction and New manufacturing Capabilities into Manufacturing and Distribution for the Bristol facility under the Kallista brand. The incumbent is responsible for project management coordination and execution of Quality and Manufacturing tasks for new products and new custom products under project sales. These responsibilities would span from process design, equipment design and procurement, execution of SOP’s and training, and validation of quality standards, while collaborating cross functionally with the project team and various members of Operations.

SPECIFIC RESPONSIBILITIES

• Functions as the Operations lead on all New Product Introductions and any new manufacturing capabilities needed to support new products strategies, working cross functionally with New Product Development, Marketing, and Supply Chain to introduce new products on‑time and within the scope of business objectives. Suggest improvements to the NPI process as needed.
• Provides input to the NPD team on design for manufacture and process capabilities with Safety / Ergonomic and Quality considerations. Supports make vs. buy decisions with supporting analysis.
• Leads the Process Failure Mode and Effect Analysis for the plant during product launch phases as well as implementation of action plans to reduce risks. Help create Control Plans for new products working with Supply Chain and suppliers to ensure vendor control plans are in place along with Quality Engineering. Works with Quality Engineer and New Product Development Engineering on determination of inspection, gaging and testing frequencies, methods, and location in production sequence; implementation with production and distribution.
• Completes product routings and costings for new products as part of the PCI process. To be the PCI SME for Manufacturing.
• Develop cell layouts, process flows, and SOPs/training documentation necessary for new product launches and new manufacturing competencies, then provides necessary training to associates. Provides technical support to production and distribution during launch / post launch phases.
• Complete post launch analysis to identify areas of improvement in both process and product design (i.e. Quality, Efficiency, and Delivery performance).
• Investigates and recommends methods to identify, reduce, or eliminate causes for non‑conforming material during product launch phases.
• Working collaboratively, direct and coordinate product and process manufacturing modifications as needed to improve quality, meet customer requirements, and to reduce inventory or lower costs. Be a Continuous Improvement Leader through utilizing Kohler Operating System principles and tools to drive continuous improvement initiatives.

Skills/Requirements

• Bachelor’s degree in engineering from ABET accredited engineering program required.
• Minimum of 6 years of engineering or related experience within a production assembly environment. Experience with automated equipment and integration preferred.
• Experience in: glass or metal fabrication product & process capabilities, evaluating metal stamping-tooling & die process improvement, standards and specifications experience preferred; working with aluminum extrusion is a plus.
• Strong workingknowledgeofSolidWorksisaplus.
• SixSigma certification/LeanManufacturingtraining preferred.
• Experiencewithprojectimprovement,machineandprocessefficiencies is highly desirable.
• Abilitytoworkindependentlyandwithinateamenvironment.
• Experience in aluminum extrusion and glass-based designs, engineeredsolutions,vendorsourcingandmanufacturingintegrationarepreferred.
• Strong written and oral communication skills.
• Ability to work on complicated projects and develop cost justifications for the business.

Applicants must be authorized to work in the US without requiring sponsorship now or in the future.

We believe in supporting you from the moment you join us, which is why Kohler offers day 1 benefits. This means you’ll have access to your applicable benefit programs from your first day on the job, with no waiting period. The salary range for this position is $103,900 - $160,000. The specific salary offered to a candidate may be influenced by a variety of factors including the candidate’s experience, their education, and the work location. In addition, this position is eligible for a performance bonus/variable incentive compensation.

Why Choose Kohler?

We empower each associate to #BecomeMoreAtKohler with a competitive total rewards package to support your health and wellbeing, access to career growth and development opportunities, a diverse and inclusive workplace, and a strong culture of innovation. With more than 30,000 bold leaders across the globe, we’re driving meaningful change in our mission to help people live gracious, healthy, and sustainable lives.

About Us

It is Kohler’s policy to recruit, hire, and promote qualified applicants without regard to race, creed, religion, age, sex, sexual orientation, gender identity or expression, marital status, national origin, disability or status as a protected veteran. If, as an individual with a disability, you need reasonable accommodation during the recruitment process, please contact [e-mail]. Kohler Co. is an equal opportunity/affirmative action employer.