Senior Mechanical and Automation Engineer Job Oceanside area,California USA,Engineering

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Job Summary

Under the general supervision of the Engineering Director,
Senior Mechanical and Automation Engineer is responsible for designing, developing, and implementing mechanical and automated solutions that transform labor‑intensive, heavy‑handling membrane manufacturing operations into safe, efficient, and scalable engineered processes. This role requires multidisciplinary expertise spanning mechanical design, electrical systems, and PLC/automation programming, with a strong automation mindset and advanced proficiency in risk management tools including Process FMEA (PFMEA), Machine FMEA, Assembly FMEA, Poka Yoke error‑proofing, Risk Priority Number (RPN) management, and Control Plan governance.

Essential

Duties and/or Responsibilities

Lead and facilitate Process FMEA (PFMEA), Machine FMEA, and Assembly FMEA sessions across new and existing manufacturing equipment and processes; assign Severity, Occurrence, and Detection ratings; calculate and manage Risk Priority Numbers (RPN); and drive corrective actions to target RPN thresholds prior to production release.

Apply Poka Yoke (mistake‑proofing) principles to equipment and process designs including fixture‑based error‑proofing, sensor interlocks, visual management systems, and assembly verification mechanisms to eliminate defect escape and ensure consistent product quality in membrane production operations.

Develop, maintain, and govern Control Plans aligned with PFMEA outputs; define process control parameters, inspection frequency, measurement methods, and reaction plans; ensure Control Plans are sustained and updated as processes evolve.

Program, configure, and troubleshoot PLC‑based automation systems (Allen Bradley, Siemens, or equivalent), HMI interfaces, servo/stepper drives, pneumatic controls, and vision inspection systems to support new equipment commissioning and ongoing production reliability.

Assess, document, and formalize legacy and underdeveloped process flows, SOPs, work instructions, and engineering standards; establish a structured documentation and engineering change control system to support process repeatability, operator training, and audit readiness.

Conduct risk assessments including Job Hazard Analysis (JHA) and machine safety reviews for all new and modified equipment; ensure compliance with OSHA 29 CFR 1910, NFPA 70, ANSI B11 machine guarding standards, and Hydranautics EHS policies; integrate safety engineering controls (guarding, interlocks, E‑stop systems) into all designs.

Lead small cross‑functional project teams (engineers, technicians, contractors) through full project lifecycle: scoping, design review, procurement, installation, qualification, and production handoff; manage project schedule and budget with regular status reporting to Engineering Director.

Develop capital project business cases including ROI analysis, cost‑benefit justification, and phased implementation plans for management approval; manage vendor quotes, contractor oversight, and procurement activities within approved budget frameworks.

Partner with production, quality, maintenance, and EHS teams to resolve equipment reliability issues using structured root cause analysis methodologies (5‑Why, Fishbone, DMAIC); implement and verify sustainable corrective and preventive actions.

Other duties as assigned.

Supervisory Responsibilities

This position leads small project teams of 2–5 engineers, technicians, or contractors on a project basis. No direct supervisory authority over permanent headcount.

Minimum

Education and/or Experience

Bachelor's degree in Mechanical Engineering, Mechatronics, Electrical Engineering, or a closely related engineering discipline and 8–12 years' experience in a manufacturing engineering or automation engineering role, or equivalent combination of education and experience.

Knowledge, Skills and/or Abilities

Expert‑level mechanical…