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Manufacturing Engineer – Lean / NPI
Houston, TX (On-site)
Position Summary
APS builds automated pharmacy dispensing systems that help healthcare providers dispense medications safely and accurately. We are launching production of our latest system and starting design of the next generation, and we are looking for a hands-on, versatile Manufacturing Engineer to help make both successful.
Our manufacturing team is small and growing, and we are ramping from prototype to our first production run of 30 complex electromechanical systems. In a team like ours, everyone wears many hats. You will help set up and run the assembly line using Lean principles, own quality from incoming parts to finished systems, solve problems directly with suppliers, and bring a manufacturing voice to Engineering as we design our next-generation product.
This role is ideal for a practical, self-directed engineer who likes building things from the ground up, is as comfortable on the shop floor as in SolidWorks, and wants broad ownership and visible impact in a growing company. Reports to the Manufacturing Engineering Manager.
What You Will Accomplish
In your first 6 months
Help set up the production assembly line, including workstations, fixtures, kitting, and standard work.
Put incoming inspection and First Article Inspection (FAI) in place for our first production batches.
Launch run-off testing and failure tracking for every system we build.
In your first 12 months
Help deliver all 30 systems on schedule, with a stable, repeatable process.
Bring documented lessons learned and DFM/DFA input into the next-generation design.
Responsibilities
Production Launch & Lean Manufacturing
Help set up the assembly line, including workstations, material flow, point-of-use storage, and line balancing, working with the Manufacturing Engineering Manager, Engineering, Purchasing, Planning, and Operations.
Apply Lean tools (5S, standard work, value stream mapping, kanban, error-proofing) to build a simple, efficient, scalable process.
Design and build assembly fixtures, tooling, and test aids.
Create and maintain work instructions, routings, and BOMs in our ERP system.
Troubleshoot assembly and build issues on the floor and drive them to permanent fixes.
Quality, Reliability & Suppliers
Own the quality system for production: create inspection plans and checklists, direct the Quality Inspector, and run nonconformance and root cause/corrective action.
Lead First Article Inspections with new suppliers for sheet-metal, machined, molded, and purchased parts, using drawings and GD&T.
Develop and run final run-off and burn-in testing for every completed system; track failures and drive fixes back into design, suppliers, and process.
Make sure every system is built to the current released revision, and support the engineering change (ECO) process.
Work directly with suppliers to resolve part issues, clarify drawings, and improve cost and lead time.
Next-Generation Product Development
Partner with Engineering to apply Design for Manufacturability and Assembly (DFM/DFA) to the next-generation product.
Maintain a lessons-learned log from the current build and use it to drive the next-generation design, including part count reduction, assembly simplification, reliability, and serviceability.
Support cost reduction, COTS component evaluations, and prototype builds for new designs.
Qualifications
Required
Bachelor's degree in Mechanical Engineering.
3+ years of Manufacturing Engineering experience in an electromechanical or machine-building environment.
Hands-on Lean Manufacturing experience, including direct involvement in setting up or improving an assembly line or work cell.
Experience applying DFM/DFA and supporting new product introduction (NPI).
Strong blueprint reading and GD&T skills; comfortable using common inspection tools.
Mechanical aptitude for troubleshooting electromechanical systems (motors, sensors, pneumatics, and wiring).
Proficient in SolidWorks; working knowledge of BOMs and ERP/MRP systems.
Self-starter who is comfortable in a small team, switching between tasks, and working independently.
Preferred
Knowledge of sheet-metal fabrication, machining, and plastic injection molding processes.
Experience working with domestic and overseas suppliers, including first article inspection.
Lean Six Sigma Green Belt or higher.
Experience with medical devices or other regulated manufacturing.
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