Senior Manufacturing Engineer

Senior Manufacturing Engineer

Halo Industries has developed breakthrough technology to revolutionize a decades-old semiconductor material slicing process. Our laser-based solution minimizes waste, enhances material cost efficiency, and drives innovations across high-growth markets, including automotive, telecommunications, and power electronics. Founded in 2014 at Stanford University, Halo received significant funding in 2024, paving the way for rapid expansion, strategic customer engagement, and the launch of volume manufacturing.

We are seeking a Senior Manufacturing Engineer to provide technical expertise and drive operational excellence in our manufacturing processes. This role is critical in bridging the gap between new product design (Engineering/R&D) and efficient mass production (Production Floor). The Senior Manufacturing Engineer will be the technical expert responsible for process definition, control, documentation, and continuous improvement on the manufacturing line.

The primary responsibility is to ensure a smooth, reliable, and well-documented transition of products and processes from the R&D/Engineering phase to high-volume manufacturing.

• R&D/Production Liaison: Act as the technical handshake between Research & Development and Production. Translate design intent, specifications, and performance requirements into clear, executable manufacturing processes.
• New Product Introduction (NPI) Support: Participate in product design reviews, ensuring adherence to Design for Manufacturability (DFM) and Design for Assembly (DFA) principles to prevent issues before they reach the floor.
• Manufacturing Process Definition: Design, develop, and qualify new production equipment, tooling, and fixtures required for product assembly and testing.
• First-Run Analysis: Lead and support initial production runs, collecting data and providing immediate, root-cause corrective actions to resolve process or product issues encountered during ramp-up.

Ensure that all manufacturing processes are standardized, controlled, and accurately documented to maintain quality and repeatability.

• Process Documentation Management: Author, audit, and maintain core manufacturing documentation, including:
• Operator Method Sheets (OMS) or Standard Operating Procedures (SOPs): Create detailed, visual, and easy-to-follow work instructions for all production steps, including assembly, inspection, and testing.
• Recipe Management: Define, release, and control the parameters ("recipes") for critical automated processes (e.g., welding, curing, CNC machining) to ensure product consistency.
• Quality Control Plans (QCP) and PFMEAs:
• Develop and release comprehensive Control Plans that define critical product characteristics, process parameters, required inspection points, and reaction plans for non-conformances.
• Lead or support Process Failure Mode and Effects Analysis (PFMEA) activities to proactively identify and mitigate risks in the manufacturing process.
• Training and Deployment: Communicate, relay, and train production team leaders and operators on new Control Plans, OMS, and revised procedures. Ensure all documentation is accessible and current on the production floor.

Drive a culture of efficiency, quality, and waste reduction using structured continuous improvement methodologies.

• Lean and Kaizen Leadership: Actively identify, lead, and facilitate Kaizen events and projects to improve process efficiency, reduce waste, and decrease cycle time.
• 5S Implementation: Champion the adoption and maintenance of 5S (Sort, Set in Order, Shine, Standardize, Sustain) methodology on the production floor to improve organization, safety, and visual management.
• Root Cause Analysis (RCA): Apply systematic problem-solving methods (e.g., 8D, Six Sigma, 5 Whys) to understand and permanently resolve chronic production events or quality issues.
• Metrics and Reporting: Monitor key performance indicators (KPIs) such as scrap rate, cycle time, first-pass yield (FPY), and overall equipment effectiveness (OEE) to target and measure the success of continuous improvement initiatives.