Sr. Lead Process Engineer

Who are we?

XNRGY Climate Systems is a North American leader in sustainable design and advanced manufacturing of custom air treatment and liquid cooling systems. We deliver innovative, energy-efficient solutions for industries such as hyperscale data centers, healthcare facilities, pharmaceutical labs, semiconductor clean rooms, EV battery manufacturers, and life sciences facilities. We are expanding rapidly, with two new state‑of‑the‑art production facilities in Mesa, Arizona launching in 2025.

This growth reflects our commitment to advancing sustainable infrastructure solutions that support the AI revolution and other critical industries.

As part of this expansion in the US, XNRGY is seeking a qualified and experienced on‑site Sr. Lead Process Engineer to join the team. Reporting to the Site Director, this position will oversee continuous improvement and sustainment of manufacturing processes to maximize efficiency and ensure proper quality.

The position of Sr. Lead Process Engineer is responsible for leading the design, optimization, and sustainment of manufacturing and assembly processes to improve product quality, efficiency, and scalability. The role focuses on hands‑on manufacturing engineering activities within a production environment and supports both ongoing operations and new product launches. Essential duties include leading the design, optimization, and sustainment of manufacturing and assembly processes to improve product quality, efficiency, and scalability;

analyzing manufacturing and production processes to identify inefficiencies and implement continuous improvement initiatives; providing technical guidance and functional leadership to engineers and production personnel, including oversight of work activities performed by technicians and other industrial engineers supporting manufacturing process improvement and production operations; developing, maintaining, and sustaining manufacturing work instructions and process documentation, including within Manufacturing Execution Systems (MES), to support production operations and quality requirements;

performing line balancing, cycle‑time analysis, and labor optimization to support takt time and production volume targets; designing, specifying, and supporting tooling, fixtures, assembly aids, and manufacturing equipment for manual and semi‑automated production processes; supporting New Product Introduction (NPI) activities, including pilot builds, process validation, tooling readiness, and transition to full production; conducting manufacturing risk analysis, including Process Failure Mode and Effects Analysis (PFMEA), and supporting implementation of process risk‑mitigation actions throughout production and new product introduction activities;

implementing error‑proofing (poka‑yoke) and process risk mitigation solutions to reduce defects, variation, and rework; collaborating closely with operations, engineering, quality, and supply chain teams to resolve manufacturing issues and support ongoing production operations; coordinating with external vendors and suppliers to support equipment design, process optimization, and capacity improvements; and developing manufacturing layouts and process flow designs using CAD‑based tools to support efficient factory layout and material flow.

This position supervises the work of a multi‑disciplinary team of engineering and technical personnel, including engineers, engineering technicians, and maintenance staff, supporting manufacturing processes, equipment, and production operations. Required travel:
Up to 10% or less, including occasional domestic and international travel related to vendor and operational needs.

Bachelor’s degree or higher in Electronic Engineering, Electrical Engineering, Industrial Engineering, or a closely related engineering discipline, or the foreign equivalent thereof; and 60 months of progressive work experience in manufacturing engineering or process engineering roles. Minimum experience must include developing and improving manufacturing and assembly processes in a production environment; performing line balancing, cycle‑time…