Manufacturing Engineer

Company Overview:

Schafer Industries is a premier supplier of off-highway axles and differentiated precision gearing solutions.   Established in 1934, Schafer Industries has locations in South Bend, IN, Roscoe, IL, Fredericktown, OH and Blacklick, OH.     Schafer Industries is one of the few manufacturers of integrated axle solutions in the off-highway electric vehicle market.   

Schafer serves customers in a variety of end markets including off-highway vehicles, recreational vehicles, aerospace, defense, oil & gas, material handling, powertrain, electric mobility, heavy duty trucking, agriculture, and construction.    Our mission is to leverage world class capabilities to deliver superior products and services to maximize the value for our customers, employees, shareholders, and communities.

Position Summary:

Schafer Industries is currently seeking a Senior Manufacturing Engineer for its Schafer Gear Works operation in Roscoe Illinois. 401K match. Air conditioned / heated manufacturing facility.

Pay Range: $100,000 - $125,000 annual

Why Work at Schafer Industries?

• We are a growth-oriented company with a diversified customer base.
• We are committed to a culture of safety and continuous improvement.
• You will enjoy a collaborative work environment where your talents and opinions matter.
• We provide training as well as opportunities to work on projects in support of your career development.
• You will quickly see your impact when working with the team.
• We have competitive pay and benefits to include 401(k) match and tuition reimbursement.
• We live our values of Safety, Integrity, Responsibility to Others, Customer Focus, Continuous Improvement and Accountability in all that we do.

Job Summary:        

The Senior Manufacturing Engineer is responsible for leading process development and optimization of manufacturing processes to ensure high-quality gear production and operational efficiency, drive continuous improvement efforts to support production and quality, enhance manufacturing operations by preparing routings, leading capital projects, and providing technical support and troubleshooting for customers as needed.

Essential Functions:

1. Process Development and Optimization

• Develop manufacturing process and routings to ensure success with manufacturing.
• Leverage LEAN manufacturing principles to optimize processes that enhance overall manufacturing efficiency and productivity.
• Utilize CNC Machining background to maximize equipment capabilities.

• Lead and manage large-scale projects focused on the acquisition and integration of new capital equipment. This includes overseeing the entire lifecycle from initial assessment and purchasing to installation and operational onboarding.
• Prepare control plans (QA documents) based on routing to support setup and in-process documentation for various manufacturing operations as needed.
• Engage regularly with customers to address and resolve issues, ensuring their satisfaction and the smooth operation of their gear machining processes.

1. Shop Floor Support

• Perform daily troubleshooting of complex issues, identifying root causes and implementing effective solutions to minimize downtime.
• Provide hands-on training to production team, ensuring they are proficient in operating machinery and adhering to best practices.
• Collaborate with production team leads to ensure parts are manufactured and shipped on time, addressing any issues that arise promptly.

• Assist in the setup and calibration of machines for complex parts, ensuring precision and efficiency.
• Develop comprehensive training plans in collaboration with machine OEMs when new equipment is purchased, ensuring staff are well-prepared to operate and maintain new machinery.
• Utilize LEAN methodologies on the shop floor, including the implementation of Standard Work and 6S practices to ensure consistency and quality.
• Monitor and analyze production metrics, identifying areas for improvement and implementing strategies to enhance productivity and quality.
• Identify potential gaps and constraints where new equipment might be necessary to maintain or enhance operational efficiency.
• Manage new product launches through the Production Part Approval Process (PPAP) using Advanced Product Quality Planning (APQP) techniques to ensure successful integration and that all quality standards are met.
• Ensure compliance with safety standards and regulations, fostering a safe and efficient work environment.

1. Quality Support

• Collaborate with the quality team to address and resolve any inspection issues or concerns that arise during in-process or final inspections.
• Assist machinists on the floor with their inspection techniques, providing guidance and training to ensure accurate and consistent results.
• Work closely with production teams to integrate quality control measures into daily operations, enhancing overall product quality and reliability.
• Identify, reduce, and eliminate non-conformances through proactive continuous improvement initiatives.
• Make final dispositions on non-conforming parts, ensuring appropriate corrective actions are taken to avoid future issues.
• Provide detailed rework instructions for non-conforming parts that can be fixed, ensuring they meet quality specifications before being released.
• Monitor and analyze inspection data to identify trends and areas for improvement, implementing corrective actions as needed.
• Ensure compliance with all quality standards and regulations, fostering a culture of continuous improvement and excellence.

1. Precision Tooling Management

• Oversee all complex tooling requirements, including hob cutters, shaper cutters, grinding wheels, and other specialized tools.
• Leverage advanced tooling knowledge and techniques to maximize cost-effectiveness, ensuring the correct tools are used efficiently to optimize production processes and reduce waste.
• Provide technical support and guidance to machinists and production teams, ensuring optimal use of tooling and equipment.
• Approve all drawings submitted by suppliers, ensuring they meet specifications and requirements.
• Continuously monitor and evaluate new technologies and tooling advancements that could improve company operations and productivity.
• Collaborate with suppliers and industry experts to stay informed about the latest developments in tooling and manufacturing technology.

1. Contributes to the overall effectiveness of the company by:

• Promoting Schafer’s vision and core values, ensuring alignment in all activities and decisions.
• Demonstrating strong leadership to foster a robust manufacturing culture that aligns with the company's values and goals.
• Being a proactive team player, collaborating effectively with colleagues across all departments.
• Leveraging strong problem-solving skills to address challenges and drive continuous improvement within the plant.
• Actively participating in company initiatives and projects, contributing to the overall growth and development of the organization.
• Training and mentoring new employees as needed, ensuring they are well-equipped to contribute to the company's success.
• Maintaining a positive and professional attitude, setting an example for others to follow.

Knowledge, Skills, Abilities

• Bachelor of Science in Mechanical or Manufacturing Engineering (or equivalent) required.
• Minimum 8 years of CNC machining related experience required.
• Minimum 3 years of gear manufacturing experience preferred.

• Sound understanding of Gear machine capabilities and the technical aptitude to maximize the machines full production capabilities preferred.
• Demonstrate excellent leadership of major projects through their successful delivery from concept to production.
• Proficiency in LEAN Manufacturing principles, with complete understanding of Gemba Walks, the “8” Wastes and the Value Stream Mapping of key processes.
• Excellent analytical and troubleshooting skills to resolve complex issues that arise.
• In-depth Knowledge of various materials, cutting tools, work holding, cutting parameters, and heat treats required.
• Experience with product cost estimating and quoting.
• Excellent business acumen to support the technical success of Schafer products.
• Great communication skills and ability to interface with key customers and stay current with industry trends and requirements.
• Well-developed skills in multi-tasking and prioritizing.
• Proficient in use of Microsoft Office software such as Word, Excel, PowerPoint. Experience with Solidworks preferred.
• Ability to travel to customer and supplier locations occasionally.

Working Conditions:

1. Air conditioned/heated manufacturing facility with possible exposure to noise; dust; fumes; physical, chemical, and biohazards; solvents, oils, and detergents.
2. This job is to be performed at the designated facility 100% of the time unless directed otherwise by manager/supervisor.

Schafer Industries is an EEO/AAP Employer:

Our company is committed to providing equal employment opportunity. This means that we make employment decisions on the basis of job-related qualifications, skills and abilities and not on the basis of race, color, religion, sex, sexual orientation, gender identity, national origin, disability, veteran status, or any other basis protected by law.

As a federal subcontractor, we also are required to take affirmative action, or proactive measures, to prevent discrimination.