Senior Manufacturing Engineer - Motor Windings

Job description

Job responsibilities

• Lead new product integration for motor winding products, partnering with design engineering from concept through production release to ensure designs are manufacturable, scalable, and cost-effective
• Develop, validate, and document winding processes (e.g., needle, flyer, linear, or insertion winding, hairpin or form-wound coils, lead dressing and termination, lacing, insulation systems, varnish/VPI, potting, and…
• Define process parameters, develop process flows, and perform process capability studies (e.g., DOE, SPC, Cpk, MSA) to establish robust, repeatable processes
• Specify, design, and qualify winding equipment, fixtures, tooling, and ground support equipment (GSE), including semi-automated and automated solutions that improve quality, throughput, and yield
• Develop comprehensive production process documentation, including routings, work instructions, process control plans, and PFMEAs
• Define and implement in-process and end-of-line electrical test methods for windings, such as resistance, inductance, insulation resistance, hipot, surge, and partial discharge testing
• Provide hands-on support to the technician team for prompt resolution of issues in a fast-paced production environment
• Lead troubleshooting and disposition of non-conforming (NC) winding and motor hardware through detailed work instructions

Job requirements

• Bachelor of Science in Electrical Engineering, Mechanical Engineering, Manufacturing Engineering, Materials Science, Physics, or a related field, or equivalent experience
• 7+ years of manufacturing engineering experience with electric motor, stator, rotor, or coil winding processes
• Demonstrated experience with new product introduction, including process development, process validation, and transition from prototype to production
• Experience developing and using process control tools such as PFMEA, control plans, SPC, MSA, and DOE
• Experience operating, diagnosing, and dispositioning non-conforming electromechanical or electrical hardware
• Familiarity with industry standards such as IPC-A-610, IPC/WHMA-A-620, J-STD-001 with Space Addendum, NASA-STD-8739.4, and NEMA MW 1000 (magnet wire), or equivalent automotive quality standards (e.g., IATF 16949, PPAP,…
• Proficiency in 3D CAD programs (SolidWorks or Creo Pro/E preferred)
• Experience applying DFMA principles in design development