Engineer, Manufacturing (ISO Poly Foam)

Responsibilities

• Lead the development and implementation of Foam-in-Place (FIP) manufacturing processes for automotive instrument panels.
• Support production of foam components such as: Instrument panel topper pads, Consoles, Armrests, Door Panels.
• Develop and define manufacturing process requirements based on product design, customer specifications, quality standards, and production volumes.
• Specify and develop equipment specifications (RFQs), review supplier proposals, participate in vendor selection, and manage equipment acceptance.
• Cook up equipment installation, Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), commissioning, and production validation activities.
• Troubleshoot foam processing issues, including density variation, voids, shrinkage, poor adhesion, and surface defects.
• Improve manufacturing efficiency, cycle time, and material utilization.
• Work with equipment such as high-pressure foam dispensing and mixing systems.
• Conduct root cause analysis and implement corrective actions for quality issues.
• Support APQP, PPAP, PFMEA, DFMEA, and Control Plan activities.
• Develop manufacturing documentation, including process flow diagrams, PFMEAs, control plans, work instructions, equipment standards, and standard operating procedures.
• Support prototype and pre-production builds while identifying and implementing process improvements.
• Provide hands-on support during equipment launch, production ramp-up, and early production to ensure manufacturing readiness.
• Collaborate with Quality, Product Engineering, and suppliers to resolve manufacturing and product issues using structured problem-solving methodologies.
• Develop preventative maintenance requirements and support equipment reliability initiatives.
• Train production personnel on equipment operation, process controls, troubleshooting, and safety procedures.
• Support continuous improvement initiatives focused on safety, quality, productivity, and cost reduction.
• Provide ongoing technical support after SOP to optimize production performance, implement engineering changes, and support customer launches.

Requirements

• Bachelor’s degree in engineering or a similar technical discipline OR 5 years of experience in a technical position in an ISO Foam manufacturing environment may be considered.
• Experience specifying and procuring manufacturing equipment, tooling, and automation systems.
• Experience supporting manufacturing programs through commissioning, validation, and Start of Production (SOP).
• Experience in polyurethane foam manufacturing and automotive interiors.
• Ability to read engineering drawings, CAD models, GD&T, and technical specifications.
• Strong troubleshooting, analytical, project management, and problem-solving skills.

Skills

• Proficiency in Microsoft Office software suite – Excel, Word, PowerPoint.
• Effective verbal and written communication skills.
• Independent thinking with strong analytical and problem-solving skills.
• Flexible and able to manage multiple priorities and projects simultaneously.

Qualifications

• Agreement to complete all post-hire required training.
• A minimum score of 50 on the Wonderlic Select Assessment (Traditional Score of 26 on the cognitive portion).
• This position typically does require up to 15% travel.