Senior Manager Manufacturing & Industrial Engineering

Job Summary:

The Senior Manager, Manufacturing & Industrial Engineering leads the Manufacturing Engineering and Industrial Engineering functions responsible for converting product engineering intent into safe, repeatable, production-ready manufacturing systems. The role owns the engineering processes that translate engineering bills of material (eBOMs) into manufacturing bills of material (mBOMs), routings, manufacturing methods, tooling requirements, standard work, and work instructions. The position also leads plant and value-stream layout development, capacity modeling, manufacturing simulation, equipment requirements, equipment capacity analysis, labor and workstation

planning, and production-system design for new and expanding operations.

This leader partners with Product Engineering, Operations, Quality, Supply Chain, Material Flow, Maintenance, Facilities, Strategic Capital Projects, Safety, and Continuous Improvement. Manufacturing & Industrial Engineering designs, industrializes, launches, and technically governs the manufacturing system. The Continuous Improvement organization owns structured improvement within established plants after processes have transitioned to sustained operations.

Minimum Qualifications: (Education, Experience, Knowledge, and Skills):

• Bachelor's degree in Manufacturing Engineering, Industrial Engineering, Mechanical Engineering, or a related engineering discipline required; master's degree preferred.
• 6+ years of progressive experience in manufacturing engineering, industrial engineering, manufacturing operations, or a related technical field, including leadership of engineering teams.
• Demonstrated experience translating product designs and eBOMs into mBOMs, routings, manufacturing methods, standard work, and production documentation.
• Strong experience with plant layout, value-stream design, capacity analysis, equipment planning, production flow, labor modeling, workstation design, and line balancing.
• Experience using manufacturing simulation, analytical modeling, or digital engineering tools to evaluate production scenarios, constraints, equipment utilization, staffing, and facility requirements.
• Experience supporting new product introduction, facility expansion, new production lines, major equipment installations, or greenfield manufacturing launches.
• Experience in complex, high-mix, engineered-to-order, or configure-to-order manufacturing environments preferred.
• Working knowledge of Design for Manufacturability, Design for Assembly, ergonomics, process capability, production readiness, and manufacturing change control.
• Strong leadership, communication, project management, problem-solving, and cross-functional decision-making skills.
• Ability to establish common engineering standards across multiple plants while maintaining clear accountability for execution at the site and value-stream levels.

Job Duties and Responsibilities:

• Leadership and Engineering Strategy
  • Lead, develop, and align the Manufacturing Engineering and Industrial Engineering teams across the manufacturing organization.
  • Establish common engineering standards, methods, governance, tools, and deliverables for manufacturing system design and product industrialization.
  • Develop the manufacturing and industrial engineering roadmap required to support volume growth, product complexity, additional shifts, facility expansion, and new plant launches.
  • Define decision rights, technical ownership, and handoffs among Product Engineering, Manufacturing Engineering, Industrial Engineering, Operations, Continuous Improvement, and supporting functions.
  • Build a scalable engineering capability that creates reusable standards and reduces plant-specific or one-off manufacturing solutions.
• Manufacturing Engineering
  • Own the process for translating engineering designs and eBOMs into accurate mBOMs, routings, operations, work centers, and executable manufacturing processes.
  • Define manufacturing methods, process sequences, standard work, work instructions, tooling, fixtures, gauges, and production documentation required for release to manufacturing.
  • Lead Design for Manufacturability and Design for Assembly reviews with Product Engineering and ensure manufacturing requirements are considered early in the product-development process.
  • Establish manufacturing readiness criteria and lead industrialization activities for new products, engineering changes, and product transfers.
  • Ensure technical manufacturing standards, process controls, tooling requirements, and documentation are validated before transition to sustained production.
  • Provide technical engineering support when production issues require changes to manufacturing methods, tooling, fixtures, equipment, or process design.
• Industrial Engineering
  • Develop current-state and future-state plant, department, value-stream, production-line, and workstation layouts.
  • Create capacity models across equipment, processes, labor, work centers, utilities, and facilities to support operating plans and long-range growth decisions.
  • Develop manufacturing simulations and scenario analyses to evaluate production strategies, volume changes, staffing levels, equipment investments, space constraints, and alternative flow concepts.
  • Determine equipment requirements, quantities, technical capabilities, utilization targets, and required capacities based on demand, product mix, process requirements, and manufacturing strategy.
  • Identify manufacturing constraints and recommend engineered solutions involving layout, equipment, automation, labor, sequencing, or process redesign.
  • Lead workstation design, labor planning, ergonomic considerations, launch-stage line balancing, and production-system validation.
  • Partner with Supply Chain and Material Flow Engineering to ensure layouts support efficient receiving, storage, supermarkets, point-of-use presentation, replenishment, WIP control, and internal logistics.
• Plant Expansion and Capital Planning
  • Provide manufacturing and industrial engineering leadership for new facilities, facility expansions, new production lines, and major manufacturing transformations.
  • Translate demand forecasts and product strategy into space, equipment, labor, infrastructure, and capital requirements.
  • Develop conceptual manufacturing layouts, process concepts, equipment strategies, capacity assumptions, and technical scopes for capital projects.
  • Partner with Strategic Capital Projects, Facilities, Operations, Safety, Maintenance, Quality, and Supply Chain during design, selection, installation, commissioning, and production ramp-up.
  • Establish and validate manufacturing readiness, capacity, and technical acceptance criteria before releasing new equipment, lines, or facilities into sustained production.
• Partnership with Continuous Improvement and Operations
  • Design manufacturing systems using Lean principles while recognizing that the Continuous Improvement organization owns structured improvement within established plants.
  • Establish a clear transition from engineering-led industrialization, launch, and stabilization to Operations ownership and
  • Continuous Improvement support after the process reaches sustained production.
  • Partner with Continuous Improvement when established operations require engineering analysis, simulation, time studies, capacity modeling, equipment changes, layout redesign, automation, or fundamental changes to manufacturing methods.
  • Incorporate lessons learned from Operations and Continuous Improvement into future product industrialization, plant designs, equipment specifications, manufacturing standards, and launch processes.
  • Evaluate successful plant improvements for standardization and deployment in future facilities, production lines, and product introductions.
• Leadership and Performance Management
  • Recruit, coach, and develop manufacturing and industrial engineering talent and establish clear performance expectations and succession plans.
  • Establish measurable engineering deliverables associated with manufacturing readiness, documentation accuracy, capacity validation, equipment performance, launch execution, and standardization.
  • Manage departmental priorities, resources, budgets, and project commitments in alignment with manufacturing strategy and business needs.
  • Communicate risks, assumptions, capacity constraints, capital needs, and recommended decisions to senior leadership in a clear and fact-based manner.

Working Conditions:

• This position is hybrid.
• Occasional travel may be required for training or meetings.
• Must be able to work flexible hours to accommodate different time zones (Central/Eastern/Mountain/Pacific), if necessary.
• Be flexible for after-hours tasks, as needed.

The above statements are intended to describe the general nature and level of work being performed by individuals assigned to this position. They are not intended to be an exhaustive list of all responsibilities, duties, and skills required. Management reserves the right to assign or reassign duties and responsibilities at any time, based on business needs.

PowerSecure is an equal opportunity employer where an applicant's qualifications are considered without regard to race, color, religion, sex, national origin, age, disability, veteran status, genetic information, sexual orientation, gender identity or expression, or any other basis prohibited by law.