Staff Manufacturing Process Engineer

About Mainspring Mainspring Energy manufactures and delivers fuel-flexible, low-emissions local power solutions that rapidly add new capacity and deliver reliable, affordable, and sustainable electric power. The company began commercial shipments of its Mainspring Linear Generators in 2020 and today has hundreds of megawatts in advanced development and field operations for leading Fortune 500 companies, data centers, and utilities. Mainspring also partners with global energy leaders including AEP, NextEra Energy Resources, Schneider Electric, and more. The core values that ground our work, guide our decisions, and connect us together: Pragmatic Optimism Excellence without Ego Proactive Collaboration

We are seeking a highly capable Senior/Staff Manufacturing Process Engineer with a strong foundation in manufacturing process planning, industrial engineering, and data-driven problem-solving to bridge the gap between product development and scalable manufacturing. In this role, you will partner closely with Mechanical, Electrical, Manufacturing, Quality, and Supply Chain teams to develop robust, scalable manufacturing processes that enable safe, repeatable, and high-volume production. You will drive end-to-end process planning, PFMEA workshops, risk mitigation strategies, process validation, and quality planning to ensure new products launch successfully and existing products continuously improve. This is not a downstream execution role. You will proactively influence product and process decisions by leveraging shop floor data, structured experimentation, and lessons learned from production to eliminate manufacturing risks before they impact volume production. The ideal candidate combines strong process engineering fundamentals, lean manufacturing principles, and hands-on manufacturing experience, and thrives in a fast-paced, highly collaborative environment where continuous improvement is part of the daily culture.

Manufacturing Process Development Develop, validate, and optimize manufacturing processes from early prototype builds through high-volume production Lead manufacturing process validation activities using PFMEA, DOE, capability studies (Cpk), and GR&R Drive cross-functional, closed-loop risk mitigation plans by partnering with Design Engineering, Quality, and Operations Establish manufacturing readiness plans, process validation strategies, and quality gates for new product introductions Manufacturing Optimization & Operational Excellence Partner with Industrial Engineering to evaluate cycle times, line balancing, and resource utilization using Yamazumi charts and time studies Drive touch-time reduction initiatives through process optimization, improved assembly sequencing, ergonomic improvements, fastening strategies, automation opportunities and subsystem testing Lead structured root cause investigations using 8D, 5 Whys, DOE, and statistical analysis to improve first-pass yield and process capability Identify and eliminate manufacturing bottlenecks to improve throughput, labor productivity, and overall equipment effectiveness (OEE) Champion Lean Manufacturing, error-proofing (Poka-Yoke), standardization, and continuous improvement initiatives across production Manufacturing Scale-Up Own the transition of assembly processes from prototype builds to scalable production systems Partner with Quality, Supply Chain, Operations, and NPI teams to successfully launch new manufacturing processes Support factory layout development, production line design, capacity planning, and equipment selection Support new factory launches, manufacturing transfers, and production ramp activities across domestic and international sites

7–10+ years (Senior) or 10–15+ years (Staff) of manufacturing/process engineering experience supporting complex electromechanical products Expertise in PFMEA, Control Plans, Process Flow Diagrams, DOE, SPC, 8D, Cpk, and GR&R Experience developing scalable manufacturing processes and supporting New Product Introduction (NPI) from prototype through high-volume production Experience developing assembly equipment, fixtures, gauges, and automation systems Strong knowledge of Lean Manufacturing, Six Sigma, Kaizen, line balancing, Yamazumi charts, time studies, and capacity modeling Proven ability to lead cross-functional technical initiatives and influence engineering decisions through data Experience working in fast-paced NPI environments with evolving designs and manufacturing challenges Experience in automotive, aerospace, energy, or other high-volume electromechanical manufacturing environments

Hands-on mindset—you enjoy working on the production floor to validate ideas, troubleshoot issues, and implement improvements Comfortable making technical decisions in ambiguous situations while balancing quality, cost, schedule, and manufacturability Passion for Lean Manufacturing with a bias toward simple, robust, and cost-effective solutions over unnecessary complexity Strong systems thinking with the ability to connect product design, manufacturing processes, quality, and operational performance

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