Senior Manufacturing Engineer (Automotive)

Staff Solutions; Akasia; On-site; ZAR 900,000 - 1,200,000; Full time

Job summary

Staff Solutions seeks a seasoned Manufacturing/Industrial Engineer to lead Root Cause Analysis, support PLC-based automation, and drive manufacturing readiness for new equipment in an automotive sewing environment.

The role emphasizes data-driven improvements, KPI analysis, technical leadership, and supplier management to deliver sustainable engineering solutions.

Qualifications

• Bachelor’s degree in mechanical engineering, Industrial Engineering, or equivalent.
• 7+ years manufacturing experience in a manufacturing environment.
• 5+ years direct engineering experience in sewing manufacturing environment.
• Automotive manufacturing experience is essential.
• Knowledge of Quality Core Tools APQP, PPAP, PFMEA, MSA, SPC.
• Strong structured problem-solving skills (5 Whys, G8D, Fishbone, A3).
• Proven experience in process optimization and industrial engineering.

Responsibilities

• Lead RCA activities for major production losses, quality concerns, and equipment failures.
• Support PLC-based manufacturing systems and production automation.
• Lead manufacturing readiness for new equipment installations and process changes.
• Analyse engineering and production KPIs and identify trends.
• Coach and mentor Manufacturing Engineers and Technicians.
• Challenge suppliers on technical solutions and drive sustainable improvements.

Skills

Root Cause Analysis

PLC troubleshooting

Project management

Manufacturing data analysis

Leadership

Education

Bachelor’s degree in mechanical engineering, Industrial Engineering, or equivalent

Tools

APQP

PPAP

PFMEA

MSA

SPC

Job description

Duties:

Root Cause Analysis & Problem Solving:

• Lead Root Cause Analysis (RCA) activities for major production losses, quality concerns, and equipment failures
• Apply structured problem-solving methodologies, including 5 Why, Fishbone Diagram, A3, PFMEA, and G8D
• Ensure corrective and preventive actions are effectively implemented and sustained
• Promote a culture of structured problem solving throughout the manufacturing team

Automation & Control Systems Support:

• Support PLC-based manufacturing systems and production automation
• Troubleshoot manufacturing equipment and production system failures
• Support integration between PLCs, MES, End-of-Line (EOL) testing systems, RFID systems, and torque control systems
• Drive initiatives to reduce supplier dependency by strengthening internal technical capability

Equipment Industrialization & New Product Launch Support:

• Lead manufacturing readiness activities for new equipment installations and process changes
• Coordinate equipment suppliers during installation, commissioning, validation, and final buy-off
• Support Run@Rate activities, capability studies, and process validation

Manufacturing Data Analysis:

• Analyse engineering and production KPIs, including:
• MTTR (Mean Time to Repair)
• MTBF (Mean Time Between Failures)
• Downtime
• Scrap
• First Time Through (FTT):
• Identify trends and implement data-driven improvement initiatives

Technical Leadership:

• Coach and mentor Manufacturing Engineers and Engineering Technicians
• Develop troubleshooting guides, engineering standards, and best practices
• Build internal engineering capability through knowledge sharing and technical development

Supplier Technical Management:

• Challenge suppliers on technical solutions and engineering improvements
• Review supplier Root Cause Analysis reports and corrective actions
• Drive sustainable engineering solutions rather than temporary fixes
• Monitor supplier technical performance and Service Level Agreement (SLA) commitments

Minimum requirements:

• Bachelor’s degree in mechanical engineering, Industrial Engineering, or an equivalent engineering qualification
• 7+ years' manufacturing experience within a manufacturing environment
• 5 + years' direct engineering experience within a sewing manufacturing environment
• Automotive manufacturing industry experience is essential
• Thorough understanding of Quality Core Tools (APQP, PPAP, PFMEA, MSA, SPC)
• Strong knowledge and practical application of structured problem-solving methodologies, including 5 Whys, G8D, Fishbone Diagram, and A3
• Proven experience in manufacturing process optimization and industrial engineering

Key Skills and Competencies:

• Strong PLC troubleshooting and automation experience
• Excellent Root Cause Analysis capability
• Project management experience
• Manufacturing data analysis and KPI reporting
• Strong leadership and coaching skills