Senior Manufacturing Engineer

Position Overview

Trojan Battery Company is seeking a Senior Manufacturing Engineer to join our team in a high-growth, innovation-driven manufacturing environment. This role is responsible for leading process design, automation, and continuous improvement initiatives, with a strong emphasis on PLC-controlled manufacturing systems, equipment reliability, and process capability.

Areas of Focus

• Lead and support automation-driven process improvements using PLC-controlled equipment
• Drive process stability, equipment uptime, and yield improvements through controls optimization and root-cause analysis
• Lead capital projects involving automated equipment, PLC upgrades, line expansions, and capacity improvements
• Act as a technical escalation point for complex process and equipment issues

Responsibilities

• Determine how key functions in a process are identified, defined & controlled
• Provide senior-level technical support for Allen-Bradley PLC-controlled manufacturing equipment (ControlLogix / CompactLogix environments)
• Improve capability through statistically screening variables that have the greatest impact to our process
• Troubleshoot and debug PLC logic, I/O, sensors, actuators, VFDs, and servo systems
• Provide process and operations support and input to cross functional teams
• Ensure that Lean manufacturing principles are applied for waste removal and ergonomics within all aspects of system, lines, and cells design
• Capable of improving all production machines
• Retain responsibility for all project expenditures and ensure assigned projects are delivered on time and on budget
• Establish a safe and ergonomically correct work environment
• Prepare engineering documents including, Process Flow Diagram, pFMEA, Standard Operation Sheets, Job Element Sheets, and related time studies, cost estimates, line and cell balancing, standard operation sheets, capital expense requests, project schedules, design specifications, equipment specifications, and construction specifications
• Define equipment standards, automation requirements, and functional specifications for new capital equipment
• Own assigned capital project budgets, schedules, and execution
• Lead improvements in Corrective, Preventive, and Predictive Maintenance strategies, with focus on control system reliability

Basic Qualifications

• 5–8+ years of experience in a manufacturing environment with automated and PLC-controlled equipment
• Bachelor’s degree in Electrical, Electronic, Mechanical, or Electro-Mechanical Engineering (preferred)
• Proven hands-on experience troubleshooting Allen-Bradley PLC systems
• Solid understanding of industrial automation components (sensors, VFDs, servos, HMIs, safety circuits)
• Strong project management skills with capital equipment experience
• Ability to think strategically while remaining hands-on and floor-focused
• Strong analytical, problem-solving, and financial acumen
• High proficiency in Microsoft Office, AutoCAD, and statistical software
• Excellent technical writing and documentation skills
• Ability to work under pressure and support off-shift troubleshooting as needed

Preferred Qualifications

• Battery Knowledge/Experience
• Six Sigma Green or Black Belt