Job Description Summary

The Lead Methods and Process Engineer is responsible for leading the development, standardization, and continuous improvement of manufacturing methods and processes across circuit breaker and instrument transformer production. This role provides technical leadership in manufacturing engineering by establishing robust manufacturing standards, optimizing production methods, and driving operational excellence initiatives that improve safety, quality, delivery, and cost.

The position serves as the subject matter expert for manufacturing methods, Lean manufacturing, and process engineering while partnering with Production, Quality, Design Engineering, Supply Chain, and EHS to ensure scalable, efficient, and reliable manufacturing operations. The Lead Methods and Process Engineer also mentors manufacturing engineers, supports strategic capital projects, and leads process transformation initiatives that align with business objectives.

Job Description

Roles and Responsibilities

• Lead the development, implementation, and governance of manufacturing methods and process standards across circuit breaker and instrument transformer production.
• Own manufacturing process documentation, including Standard Work, process flows, work instructions, routing structures, and manufacturing specifications.
• Lead and facilitate Process Failure Mode and Effects Analysis (PFMEA), ensuring risks are identified, mitigated, and periodically reviewed.
• Define and maintain manufacturing best practices and ensure consistency across production lines.
• Design, develop, and implement manufacturing fixtures, tooling, and ergonomic solutions that improve safety, quality, productivity, and operator experience.
• Lead manufacturing process optimization initiatives focused on throughput improvement, cycle time reduction, labor optimization, Overall Equipment Effectiveness (OEE), and waste elimination.
• Drive Lean Manufacturing initiatives including Value Stream Mapping, Kaizen Events, 5S, Visual Management, Standard Work, SMED, and Daily Management.
• Support strategic capacity planning, line balancing, facility layout optimization, and manufacturing footprint improvements through 2D Simulation projects.
• Lead manufacturing readiness activities for New Product Introduction (NPI), product transfers, and process validation.
• Develop manufacturing process metrics and dashboards to monitor process capability, productivity, quality, and operational performance.
• Utilize data analysis tools to identify trends, drive root cause analysis, and prioritize improvement opportunities.
• Lead cross-functional problem-solving efforts using structured methodologies such as A3, DMAIC, 8D, and Root Cause Analysis.
• Coordinate and lead Management of Change (MOC) activities affecting manufacturing processes, equipment, and documentation.
• Own production routing management, labor standards, and time studies to ensure accurate manufacturing planning and cost models.
• Support capital investment projects by defining manufacturing requirements, equipment specifications, acceptance criteria, and commissioning activities.

Required Qualifications

• Bachelor's degree in Industrial Engineering, Mechanical Engineering, Manufacturing Engineering, or a related engineering discipline.
• Minimum of 3 years of experience in manufacturing engineering, industrial engineering, methods engineering, or process engineering within a manufacturing environment.
• Demonstrated experience leading manufacturing process improvement initiatives and cross-functional technical projects.
• Experience with Lean Manufacturing implementation and structured problem-solving methodologies.

Desired Characteristics

• Strong leadership, communication, and influencing skills with the ability to lead cross-functional teams without direct authority.
• Proven experience developing manufacturing methods, process standards, and production systems.
• Advanced knowledge of Lean Manufacturing, Six Sigma, Industrial Engineering, and Operational Excellence principles.
• Experience leading PFMEA, Control Plans, Standard Work, and process validation activities.
• Strong understanding of manufacturing fixtures, tooling design, ergonomics, and process optimization.
• Experience with SAP or other ERP systems is a plus