Senior Staff Engineer - Manufacturing Engineering

Senior Staff Engineer – Manufacturing Engineering

We are looking for a Senior Staff Engineer – Manufacturing Engineering to be a key technical and operational leader responsible for driving overall site performance across safety, quality, delivery, cost, and productivity. This role goes beyond traditional manufacturing engineering and owns cross‑functional execution in a small‑site environment, including capital projects, new product integration, systems implementation, and operational readiness.

• Drive production performance by ensuring efficient operations, meeting output goals, and maintaining high‑quality standards.
• Establish and optimize manufacturing processes, workflows, and material flow to maximize throughput, efficiency, and scalability.
• Identify and implement process improvements to enhance safety, quality, productivity, and cost efficiency, ensuring rapid containment, root‑cause identification, and permanent corrective actions.
• Lead continuous improvement initiatives using Lean methodologies (DMAIC, PDCA, A3).
• Implement error‑proofing (Poka‑Yoke), standardized work, and visual management systems.
• Partner with design engineering to ensure products are optimized for manufacturability (DFM/DFA) and support new product launches.
• Develop and maintain manufacturing processes, routings, and material flow to maximize throughput and resource utilization.
• Own and lead capital projects (CAPEX) from concept through implementation, including budgeting, vendor selection, installation, and validation.
• Serve as the primary project manager for site‑level initiatives, ensuring timelines, cost, and scope are met.
• Lead end‑to‑end industrialization of new products.
• Own production readiness, including tooling, process capability, operator training, and documentation.
• Perform other duties as assigned.

• Bachelor of Science (from an ABET‑accredited institution) in Mechanical Engineering, Industrial Engineering, Manufacturing Engineering, or a related technical field.
• 5+ years of relevant experience in manufacturing, process engineering, or project engineering.
• Proven experience owning projects and delivering measurable results.
• Advanced problem‑solving capability at both system and subsystem levels.
• Experience leading capital projects and equipment implementation.
• Strong mechanical and process aptitude.
• Excellent communication and interpersonal skills and ability to lead cross‑functional teams.
• Lean Six Sigma Green Belt (or equivalent demonstrated experience);
  Black Belt preferred.
• Experience drawing accurate conclusions from test data, malfunctions, or deviations, and assisting with corrections to the existing design or process.
• Ability to manage multiple projects of moderate scope and complexity simultaneously while handling high‑priority initiatives as needed.
• Be innovative, resourceful, and work with minimal direction.
• Applicants must be authorized to work in the U.S. without requiring sponsorship now or in the future.

Salary range: $ – $.

Rehlko is an equal opportunity employer that prohibits discrimination and will make decisions regarding employment opportunities, including, but not limited to, hiring, job assignment, compensation, promotion, benefits, training, discipline, and termination, without regard to race, creed, color, ethnicity, religion, sex, pregnancy, childbirth, or related medical conditions, genetic information, age, national origin, citizenship, ancestry, caste, mental or physical disability, marital or familial status, sexual orientation, gender identity or expression, disability, political belief or affiliation, union membership status, military status, veteran status, or any other characteristic protected by national, state, or local laws.

Rehlko complies with the Americans with Disabilities Act (ADA) and provides reasonable accommodations to qualified individuals with disabilities.