Requirements
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Our client, a global leader in advanced technology and highly regulated manufacturing, is seeking an experienced Senior Industrial Engineer – NPI & Manufacturing Scale-Up to support new product introduction, product launch, and the scaling of complex manufacturing operations.
This position will play a key role in transitioning products from NPI through production launch and volume manufacturing, with a strong focus on capacity planning, manufacturing line design, layout optimization, process flow, material flow, line balancing, and operational efficiency.
The ideal candidate will bring strong hands-on Industrial Engineering experience within a high-volume manufacturing environment and have direct experience supporting new product launches and production ramp-ups.
This is a hands-on role for an Industrial Engineer who can evaluate manufacturing systems, develop capacity and layout strategies, identify constraints, and implement scalable solutions as products move into production.
Key Responsibilities
NPI, Product Launch & Manufacturing Scale-Up
Support new product introduction from early manufacturing planning through product launch and production ramp-up.
Develop manufacturing strategies to successfully scale products from NPI into volume production.
Evaluate manufacturing requirements including labor, equipment, floor space, capacity, and production flow.
Support new manufacturing lines, work cells, equipment installations, and production expansions.
Partner cross-functionally with Manufacturing, Engineering, Operations, Quality, Supply Chain, and other teams to ensure manufacturing readiness.
Identify and resolve production constraints during product launch and ramp.
Industrial Engineering & Manufacturing Optimization
Conduct time studies, cycle-time analysis, takt-time analysis, line balancing, and work measurement.
Analyze and optimize manufacturing process flow, material flow, information flow, and personnel movement.
Design and optimize manufacturing lines, work cells, equipment placement, and facility layouts.
Identify bottlenecks and implement improvements to increase throughput, productivity, capacity, and labor efficiency.
Apply Lean and continuous improvement methodologies to improve manufacturing performance.
Develop scalable manufacturing processes that support increasing production volumes.
Capacity Planning & Modeling
Develop capacity models based on production forecasts, cycle times, equipment availability, labor requirements, yield, and other operating constraints.
Determine manpower, equipment, floor-space, and production-line requirements necessary to meet demand.
Perform capacity analysis across multiple manufacturing lines and identify future constraints.
Evaluate alternatives before recommending additional headcount, equipment, or capital investment.
Support short- and long-range manufacturing capacity planning.
Manufacturing Layout & Flow
Develop and optimize manufacturing layouts using AutoCAD or similar tools.
Evaluate workstation placement, equipment utilization, material movement, operator movement, and overall production flow.
Support greenfield, brownfield, line expansion, and manufacturing reconfiguration projects.
Develop future-state layouts that support product launch, production ramp, and long-term capacity requirements.
Analytics & Continuous Improvement
Analyze manufacturing data to identify trends, bottlenecks, capacity constraints, and improvement opportunities.
Monitor key metrics including cycle time, throughput, productivity, labor utilization, WIP, capacity, and efficiency.
Develop data-driven recommendations and present findings to engineering, operations, and management teams.
Lead cross-functional improvement projects from analysis through implementation and validation.
Qualifications and Job Information
Qualifications
Bachelor's degree in Industrial Engineering or a related engineering discipline.
5+ years of Industrial Engineering, Manufacturing Engineering, Operations Engineering, or related experience.
Strong Industrial Engineering experience within a manufacturing environment.
Demonstrated experience supporting NPI, new product launch, production ramp-up, or manufacturing scale-up.
Strong experience with capacity planning and capacity modeling.
Hands-on experience with time studies, takt time, cycle time, line balancing, labor/manpower planning, and bottleneck analysis.
Experience designing or optimizing manufacturing lines, work cells, facility layouts, and process/material flow.
Experience with AutoCAD or similar layout/design tools.
Strong Excel and data-analysis capabilities.
Experience applying Lean Manufacturing and continuous improvement methodologies.
Experience in high-volume manufacturing and/or automated manufacturing environments strongly preferred.
Experience within medical device, automotive, electronics, semiconductor, aerospace, or another complex/highly regulated manufacturing environment preferred.
Experience with manufacturing simulation, ERP/MES systems, and data visualization tools is a plus.
Leadership & Competencies
Strong analytical and structured problem-solving skills.
Ability to translate production demand into practical capacity, labor, equipment, and layout requirements.
Strong understanding of manufacturing systems and traditional Industrial Engineering principles.
Proven ability to lead cross-functional projects from analysis through implementation.
Strong communication and collaboration skills.
Ability to work effectively across Manufacturing, Operations, Engineering, Quality, and Supply Chain.
Comfortable working in a fast-paced environment supporting new product launches and production ramp-ups.
Location: Santa Clara County, CA – Onsite
Travel: Minimal