PURPOSE:
The Senior Manager, Manufacturing Engineering oversees manufacturing operations, ensuring efficiency, quality, and compliance in a plant manufacturing Headborne and Optical protection systems. This role is pivotal in aligning engineering strategies with business goals, enhancing operational efficiency, and fostering innovation in manufacturing technologies. The Senior Manager, Manufacturing Engineering leads a team of Process and Manufacturing Engineers focused on sustaining and improving ongoing Operations efficiency and quality, while also driving the process of design, development, implementation, and optimization of advanced manufacturing and automation systems. This role combines leadership in process engineering, manufacturing engineering and industrial automation, focused on driving continuous improvement, new product introduction (NPI), cost reduction, and enhanced operational efficiency across a high-mix, high-volume manufacturing environment.
The ideal candidate will bring deep expertise in manufacturing processes (e.g., composites, plastics, injection molding) as well as automation technologies (e.g., PLCs, robotics), with a strong ability to lead cross-functional teams and deliver results in dynamic, fast-paced environments.
DUTIES/RESPONSIBILITIES:
Strategic Leadership: Lead, mentor, and develop a multidisciplinary team of manufacturing and automation engineers across a multishift operation, setting goals, evaluating performance and developing engineering leaders and experts for the future.
Process Optimization: Design, implement, and refine manufacturing processes to improve productivity, reduce waste, and lower costs.
Quality Assurance: Ensure compliance with industry and US Government standards, safety regulations, and internal quality protocols.
Cross-Functional Collaboration: Work closely with design engineering, product management, production, supply chain, and quality teams to support product development and launch.
Technology Integration: Evaluate and introduce new manufacturing technologies, automation tools, and digital systems. Design, qualify, and implement new manufacturing processes, tools, and automated systems to improve productivity, quality, and safety.
Data-Driven Decision Making: Analyze production metrics and KPIs to identify trends and areas for improvement. Drive continuous improvement initiatives using Lean, Six Sigma (DMAIC), and Kaizen methodologies.
Oversee end-to-end execution of automation and process engineering projects, including planning, budgeting, and resource allocation.
Identify and execute cost reduction, yield improvement, and throughput enhancement opportunities.
Collaborate with teams across design, production, quality, IT, and supply chain to support NPI and operational excellence.
Evaluate and deploy advanced technologies including robotics, machine vision, AI-enabled tools, and Industry 4.0 platforms.
Provide technical leadership for troubleshooting, root cause analysis, and corrective actions for manufacturing and automation issues.
Manage documentation including BOMs, routings, PFMEAs, SOPs, and standard work instructions.
Maintain compliance with safety regulations, quality standards (e.g., AS9100), and internal policies.
Prepare and present project updates, metrics, and proposals to senior leadership and stakeholders.
Support layout planning, capacity analysis, and capital equipment investment.
Research and purchase new manufacturing technology
Other duties as assigned
Schedule flexibility to support critical deadlines may be required.
Requirements
EDUCATION AND/OR PROFESSIONAL LICENSE(s):
Bachelor's degree in engineering (Mechanical, Electrical, Industrial, Mechatronics or related field)
Master's degree in engineering, manufacturing systems or technical management is preferred
Certifications in Lean, Six Sigma, or PMP are highly desirable.
Strong knowledge of CAD/CAM software, ERP systems (SAP preferred), and manufacturing simulation tools.
EXPERIENCE:
12+ years in manufacturing and industrial automation, with at least 5 years in a leadership role.
Proven success in NPI, from concept through full production.
Hands-on experience with composite processing, plastic extrusion, injection molding, and process troubleshooting.
Expertise in PLC programming (Allen-Bradley, Siemens), SCADA/HMI systems, robotics, and controls.
Experience managing capital projects, automation integration, and safety systems.
Experience and examples of leading change, operational transformation, teams and developing talent.
Six Sigma Green Belt Certification highly desired, with a Black Belt preferred.
KNOWLEDGE, SKILLS AND ABILITIES:
Strong knowledge of lean manufacturing, Six Sigma (DMAIC), Kaizen, and process capability analysis.
Proficient in CAD (SolidWorks or equivalent), GD&T, and engineering drawing interpretation.
Familiar with MRP/ERP systems and data analysis tools (e.g., Excel, Minitab, Visio, Project).
Excellent leadership, communication, and cross-functional collaboration skills.
Ability to manage multiple complex projects and deliver under pressure.
High analytical ability and data-driven decision-making.
Excellent coaching and talent development skills.
Proven ability to create, foster, and work in a team-oriented environment.
Demonstrated Root Cause Analysis and Problem-Solving skills.
POSITION SUPERVISES:
This position will lead, mentor, and develop the Manufacturing, Process and Automation Engineering teams.
CONTACT WITH OTHERS:
This position requires contact and interaction with a multitude of technical disciplines within GENTEX Corporation, not only within the Carbondale facility, but with "sister" plants throughout the United States.
This position will also require interaction with GENTEX suppliers and occasionally with the customer.
PHYSICAL/MENTAL/COMMUNICATION REQUIREMENTS:
Employee is occasionally required to stand; walk; sit; use hands to handle, or feel objects, tools, or controls; reach with hands and arms; climb stairs; balance; stoop, kneel, crouch, or crawl; talk or hear; and taste or smell. The employee may lift and/or move up to 50 lbs. Specific vision abilities required by the job may include close vision, distance vision, color vision, peripheral vision, depth perception, and the ability to adjust focus. The individual must have a high level of comprehension, and a high level of general, verbal, written, and numerical intelligence.
WORK ENVIRONMENT:
