Sr. Manufacturing Engineer, Busbar Fabrication

Eaton’s ES AMER ARS division is currently seeking a Sr. Manufacturing Engineer, Busbar Fabrication based onsite at any of the following Eaton locations:
Arden, NC, Charlotte, NC, Greenwood, SC, or Sumter SC. Relocation assistance is available to candidates who currently reside in the US.

The expected annual salary range for this role is $97000 - $143000 a year. Please note the salary information shown is a general guideline only. Salaries are based upon candidate skills, experience, and qualifications, as well as market and business considerations.

The Senior Manufacturing Engineer will serve as a technical busbar and copper fabrication expert supporting the development and operation of the ARS Fabrication Center of Excellence (Fab COE) and associated Satellites. This role will drive manufacturing process optimization, make-versus-buy decisions, design-for-manufacturing reviews, capacity optimization initiatives, and technology selection for copper and aluminum busbar, flexible connectors, and related current-carrying components.

• Strong technical experience with busbar and conductive-metal fabrication in high-mix and automated manufacturing environments.
• Strong technical knowledge of copper and aluminum cutting, sawing, punching, drilling, milling, bending, deburring, cleaning, joining, plating, coating, insulation, marking, and inspection processes. Understand when to use each process and in what configuration.
• Familiarity with CNC busbar processing centers, busbar punches and benders, machining systems, automated material handling, and equivalent OEM technologies.
• Develop specifications for new busbar fabrication equipment, tooling, automation, inspection systems, and material handling.
• Understanding of digital manufacturing platforms, MES integration, fabrication scheduling systems, NC programming, equipment connectivity, and ERP interfaces. DMM (Aquilla Group) experience is a plus.
• Experience with material flow automation, production logistics systems, part identification and traceability, and highly automated manufacturing architectures.
• Strong knowledge of copper and aluminum grades, temper, conductivity, mechanical properties, bend behavior, surface condition, and handling requirements for optimized process development and equipment selection.
• General knowledge and experience with bolted joints, brazing, welding, flexible connections, plating, coating, insulation, cleaning, and surface preparation.
• Conduct Design For Manufacturing (DFM) reviews for busbar, flexible connector, and conductive-component designs and assemblies.
• Partner with product engineering to improve bend geometry, hole and slot features, joint interfaces, clearances, plating requirements, insulation interfaces, dimensional control, electrical performance, material yield, and assembly access.
• Support development and implementation of busbar fabrication safety programs, including machine guarding, ergonomics, dust and fume controls, electrical safety, and material handling.
• Support new product launches with Manufacturing Launch Readiness (MLR) processes at the site level.
• Work with design engineering to incorporate DFM elements and busbar design and manufacturing standards into product development.
• Develop process controls for critical characteristics such as hole location, flatness, bend angle, joint-interface condition, coating or plating coverage, dimensional stack-up, and joint quality.
• Identify skill gaps and provide or coordinate training and technical support to site manufacturing personnel.
• Support Lean, Six Sigma, and Pro Launch through Process Maps, Standard Work, Takt Times, PFMEA, Design of Experiments, Control Plans, capability studies, measurement-system analysis, and Job Safety Analysis.
• Perform make-versus-buy analysis for part cost, capacity, quality, lead time, supplier capability, and manufacturing-network optimization.
• Build part-family, machine-capability, capacity, utilization, throughput, labor, and material-yield analyses for current and future demand.
• Work with sites to generate maintenance and technology roadmaps that sustain and improve equipment efficiency while optimizing capital.
• Support equipment justification, supplier evaluation, runoffs, installation, validation, startup, ramp-up, standard work, and preventive-maintenance plans for all related busbar fabrication processes.

• Bachelor's Degree in Engineering from an accredited institution.
• 5 years or more experience in…