Sr. Production Engineer - Electric Motors

As a Senior Production Engineer in Axial Flux Motor Manufacturing, you will be responsible for leading and optimizing manufacturing operations for next-generation Axial Flux Electric Motors. Your role will involve developing, implementing, and optimizing manufacturing processes, driving continuous improvement initiatives, and ensuring product quality from prototype to volume production. Key Responsibilities: - Develop, implement, and optimize manufacturing processes for axial flux motor components and assemblies. - Define process flows, work instructions, SOPs, and manufacturing standards. - Support industrialization and transition from prototype builds to serial production. - Establish takt time, line balancing, capacity planning, and production KPIs. - Drive continuous improvement initiatives using Lean Manufacturing and Six Sigma methodologies. Rotating Machine Assembly: - Develop assembly processes for rotor assemblies, stator assemblies, magnet installation, shaft and bearing systems, air-gap setting, and end-of-line testing. - Ensure dimensional accuracy, balancing requirements, and assembly quality of rotating systems. - Define critical process parameters affecting motor performance and reliability. Manufacturing Excellence: - Lead root-cause analysis for production defects, yield losses, and field failures. - Implement corrective and preventive actions (CAPA). - Drive OEE improvements and reduction of cycle times and manufacturing costs. - Support automation and semi-automation initiatives. Quality & Reliability: - Collaborate with Quality Engineering to establish process controls and inspection plans. - Conduct PFMEA, Control Plans, Process Capability studies, and MSA activities. - Ensure compliance with quality standards and safety requirements. - Support reliability validation and durability testing. Cross-Functional Collaboration: - Work closely with Design, R&D, Supply Chain, Quality, and Maintenance teams. - Provide Design for Manufacturing (DFM) and Design for Assembly (DFA) feedback. - Support new product introduction (NPI) activities. - Train production personnel and supervise process implementation. Job Requirements: Education: - Bachelor's or Master's degree in Mechanical Engineering, Production Engineering, Manufacturing Engineering, Electrical Engineering, or Mechatronics Engineering. Experience: - 815+ years of manufacturing or production engineering experience in industries such as electric motors, automotive powertrain, aerospace propulsion systems, or EV drivetrain manufacturing. Technical Skills: - Strong understanding of rotating machine fundamentals and experience with electric motor manufacturing and assembly. - Knowledge of rotor/stator assembly processes, magnet handling, press-fit operations, bearing installation, and torque-controlled assembly. - Experience with Lean Manufacturing, Six Sigma tools, PFMEA, Control Plans, SPC, and CAPA methodologies. - Ability to interpret engineering drawings and GD&T, and experience with ERP/MES systems. Preferred Skills: - Direct experience with Axial Flux Motors, Permanent Magnet Synchronous Motors (PMSM), high-speed electric machines, and EV traction motors. - Experience with automated assembly lines, Industry 4.0 systems, and motor testing including Back-EMF testing, dynamometer testing, vibration analysis, thermal performance validation, and NVH evaluation. Leadership & Behavioral Competencies: - Strong problem-solving and analytical skills, demonstrated leadership in manufacturing environments, effective communication, and cross-functional collaboration skills. - Ability to manage multiple projects simultaneously with a results-oriented mindset focusing on safety, quality, delivery, and cost. As a Senior Production Engineer in Axial Flux Motor Manufacturing, you will be responsible for leading and optimizing manufacturing operations for next-generation Axial Flux Electric Motors. Your role will involve developing, implementing, and optimizing manufacturing processes, driving continuous improvement initiatives, and ensuring product quality from prototype to volume production. Key Responsibilities: - Develop, implement, and optimize manufacturing processes for axial flux motor components and assemblies. - Define process flows, work instructions, SOPs, and manufacturing standards. - Support industrialization and transition from prototype builds to serial production. - Establish takt time, line balancing, capacity planning, and production KPIs. - Drive continuous improvement initiatives using Lean Manufacturing and Six Sigma methodologies. Rotating Machine Assembly: - Develop assembly processes for rotor assemblies, stator assemblies, magnet installation, shaft and bearing systems, air-gap setting, and end-of-line testing. - Ensure dimensional accuracy, balancing requirements, and assembly quality of rotating systems. - Define critical process parameters affecting motor performance and reliability. Manufacturing Excellence: -