Senior Industrial Engineer

Description

Lonestar Integrated Solutions is seeking an experienced and highly motivated Senior Industrial Engineer to lead the development, optimization, and standardization of manufacturing processes across our production operations. This role is responsible for designing scalable manufacturing systems, improving workflow efficiency, driving continuous improvement initiatives, and supporting the successful launch of new product lines and production capabilities.

The ideal candidate will possess a strong background in industrial engineering, manufacturing process design, lean principles, and operational excellence. This position requires a hands‑on leader who can analyze complex manufacturing challenges, develop practical solutions, and work collaboratively with engineering, operations, purchasing, project management, and production teams to improve safety, quality, delivery, and cost performance. The ideal candidate will be organized, communicative, and aligned with our passion to MAKE IT HAPPEN.

• Lead the design, development, and implementation of manufacturing processes for new and existing product lines.
• Analyze production requirements and develop scalable manufacturing strategies for high-volume and repeat-order production environments.
• Define and optimize production sequences from material receipt through final assembly, testing, packaging, and shipment.
• Conduct time studies and labor analysis to establish realistic production standards and performance expectations.
• Perform value-stream mapping to identify and eliminate waste, bottlenecks, inefficiencies, and non-value-added activities.
• Develop and implement line-balancing and workload distribution strategies to maximize production capacity.
• Evaluate and recommend tooling, fixtures, equipment, automation solutions, and process technologies that enhance productivity, quality, and safety.
• Create repeatable manufacturing processes to support the introduction of new product categories and production capabilities.
• Partner with engineering teams to improve product designs for manufacturability, assembly, serviceability, and cost efficiency.
• Develop capacity models and provide recommendations for future labor, equipment, facility, and space requirements.
• Establish manufacturing performance metrics and key performance indicators (KPIs).
• Analyze performance data and provide actionable recommendations for continuous improvement.
• Lead root cause investigations and corrective actions for recurring production, quality, and workflow issues.
• Support Lean Manufacturing, Six Sigma, and Continuous Improvement initiatives throughout the organization.
• Assist with production planning and operational improvement projects.
• Support business growth initiatives through manufacturing readiness planning and process development.
• Foster a culture of safety, accountability, teamwork, and continuous improvement.
• Perform other duties as assigned by leadership.

• Bachelor's degree in Industrial Engineering, Manufacturing Engineering, Mechanical Engineering, or a related technical field.
• Minimum 5 years of experience in industrial engineering, manufacturing engineering, process engineering, or manufacturing operations.
• Strong preference for experience in:
• Electrical equipment manufacturing
• Switchgear assembly
• Control panel manufacturing
• Fabrication operations
• Metalworking environments
• Engineered-to-order manufacturing
• Industrial equipment assembly
• Demonstrated experience designing and implementing manufacturing processes rather than solely maintaining existing systems.
• Proven ability to lead process improvement initiatives that deliver measurable operational results.
• Experience working in cross-functional environments that include engineering, operations, purchasing, project management, and production teams.
• Ability to translate engineering drawings, specifications, and Bills of Material (BOMs) into efficient manufacturing processes.
• Experience evaluating and implementing manufacturing equipment, fixtures, tooling, and automation systems.
• Strong analytical and problem-solving capabilities with the ability to identify opportunities for operational improvement.
• Experience utilizing ERP, MRP, MES, or manufacturing data systems preferred.
• Ability to gather, analyze, and present manufacturing performance data to support decision-making.
• Strong understanding of manufacturing safety, quality systems, and production best practices.

• Lean Six Sigma Green Belt, Black Belt, or equivalent certification.
• Experience supporting:
• UL508A panel shop operations
• Industrial electrical manufacturing
• Switchgear production
• Automation equipment assembly
• Custom engineered product manufacturing
• Experience with manufacturing simulation, facility layout planning, or capacity modeling tools.
• Familiarity with ERP/MRP systems and manufacturing reporting platforms.
• Project management experience leading cross-functional operational improvement efforts.
• Experience implementing…