Senior / Staff Manufacturing Engineer (NPI)

The role

This role leads manufacturing engineering for new product introduction. You will own APQP program management at contract manufacturing and Tier 1 sites so that production starts smoothly and PPAP deliverables are complete.

What you will do

• Own APQP program management at CM and Tier 1 sites through a smooth Start of Production (SOP)
• Give design-for-manufacturing and design-for-assembly feedback during APQP Phase 2
• Validate that sub-tier component PPAPs fit the CM's assembly process
• Define special characteristic steps for mechanical assembly, test, and integration of sensors, compute, and actuation systems
• Define, deploy, and validate End-of-Line testers and calibration routines
• Lead Process PPAP deliverables, including PFMEAs, process flow diagrams, control plans, and work instructions
• Design and qualify manufacturing equipment, tooling, and gauges, including MSA and Gage R&R
• Run Process Verification testing, including run-at-rate studies at full production speed
• Lead root cause corrective action (RCCA) using the 8D method for assembly failures
• Update manufacturing control plans using field performance data and OEM feedback

Required qualifications

• Bachelor's degree in Mechanical Engineering or a similar field
• Proven record launching automotive or high-tech hardware at Tier 1 or contract manufacturers using structured quality gates
• Experience moving hardware from prototype to a production-validated manufacturing line
• Advanced APQP and PPAP management, including control plans, process flows, Gage R&R, and process stability (Cpk)
• Experience managing the transition from Design Verification to Process Verification
• Experience overseeing full PPAP submissions for complex electromechanical systems
• Proficiency with SolidWorks for reviewing assembly fixtures, pallets, and inspection jigs
• Expertise in GD&T and metrology using CMM, OMM, or vision systems
• Mastery of 8D and RCCA problem solving under production ramp pressure
• Experience with PLM tools and document revision control for engineering change orders and BOM accuracy
• Experience with precision torque, thermal interface material dispensing, and high-stakes sensor calibration
• Ability to present manufacturing readiness to cross-functional teams using data to justify moving from APQP Phase 3 to Phase 4

Nice to have

• Automotive, aerospace, autonomous vehicle, or EV industry experience
• Knowledge of IPC/WHMA-A-620 and IPC-A-610 standards for wire harness and electronic assemblies
• Experience with robotic workcells or automated assembly systems
• Certified Quality Engineer (CQE) or Six Sigma Green or Black Belt

Benefits

• Competitive compensation and equity awards
• Medical, dental, and vision coverage (full-time employees only)
• Unlimited vacation
• Flexible hours and work-from-home support
• Daily drinks, snacks, and catered meals when in office
• Regular team building activities and social events on-site, off-site, and virtual

Before you apply

• Waabi is an equal opportunity employer; accommodations are available during the application and interview process on request

About the company

Waabi is a Physical AI company founded by Raquel Urtasun, building technology for commercial autonomous trucks and robotaxis. It has offices in Toronto, San Francisco, Dallas, and Pittsburgh.