Senior/Staff Manufacturing Engineer

The role

You will develop, test, deploy, and scale processes, inline inspection, and electrical test strategies for high-volume transformer assembly lines. You will work with potting and dispense systems, surface treatment, and high-speed plastic welding while collaborating with design teams and external suppliers.

What you will do

• Lead development of inline inspection, process monitoring and automated electrical test from concept to ramp
• Develop and deploy high-speed automated inspection of potted assemblies using X-ray/CT, ultrasonic, thermography and machine vision
• Develop surface treatments processes and inline verification of treatment uniformity and quality
• Architect and deploy automated high volume electrical test equipment
• Partner with manufacturing engineers to develop high-viscosity potting and dispense systems and high-speed plastic welding processes
• Lead MSA, Gage R&R and test method validation for inspection and electrical test systems
• Apply PFMEA, control plans, SPC methodology and structured problem solving
• Support automation integration with robots, conveyors and inline QA

Required qualifications

• Bachelor’s degree in Manufacturing/Industrial/Mechanical/Electrical/Chemical Engineering
• 7+ years of experience in high volume manufacturing with a focus on process engineering, inline inspection, production test or automation for electromechanical, power electronics, magnetics or battery
• Hands-one experience deploying automated non-destructive inspection (X-ray/Ct, ultrasonic, thermography or vision) to detect voids, delamination or bond-line defects in production
• Experience developing and validating automated electrical test for high volume production
• Experience with design, optimization and validation for high-viscosity potting and dispense systems including material supply, metering, mixing, vacuum potting and degassing strategies
• Experience with surface preparation processes and quantitative surface quality measurement
• Experience with ultrasonic, hot plate and/or IR welding of plastics, including process monitoring and weld validation
• Proficiency in statistical analysis, SPC, Cp/Cpk studies, hypothesis testing and Minitab/JMP
• Demonstrated ability to run DoE’s and optimize complex processes
• Experience implementing PFMEA’s, control plans, process flow diagrams
• Hands-on experience with automation, robotics, PLCs and vision systems

Nice to have

• Experience with injection molding processes and tooling

Benefits

• Competitive compensation (salary and equity)
• Benefits

About the company

Heron Power is a startup company building cutting-edge power electronics for the 21st-century grid. They aim to build better converters to connect large-scale renewables, storage, and loads to the grid.