The Chief Mechanical Engineer – Manufacturing and Assembly Systems is responsible for the strategic design, development, and deployment of mechanical systems and processes supporting high-performance manufacturing and complex product assembly. This role leads multidisciplinary engineering teams to deliver innovative, cost-effective, and scalable mechanical solutions for production lines, custom machinery, tooling, and automation systems. The Chief Engineer ensures robust integration between product design, process engineering, equipment development, and manufacturing operations.
Lead mechanical design, analysis, and system engineering for manufacturing and assembly processes across new and existing production lines.
Define mechanical requirements and specifications for custom automation equipment, fixtures, tooling, conveyors, and assembly stations.
Drive design for manufacturability and assembly (DFM/DFA) best practices from early product development phases.
Oversee lifecycle of mechanical systems from concept through detailed design, prototyping, validation, and commissioning.
Evaluate and select materials, actuators, linear motion systems, pneumatics, and structural elements for robust system performance.
Collaborate with electrical, controls, and software teams for full mechatronic integration.
Support plant layout planning, ergonomic design, and lean manufacturing principles in line design.
Provide technical guidance in solving complex engineering issues and continuously improve system reliability, precision, and maintainability.
Develop and maintain mechanical design standards, documentation, and engineering workflows.
Mentor a team of mechanical and manufacturing engineers, and support strategic planning and budgeting for capital investments.
Custom Equipment & Fixture Design:
Lead design of specialized machinery, jigs, fixtures, and workstations optimized for repeatability, ergonomics, and throughput.
Ensure modularity and ease of reconfiguration in tooling for flexible manufacturing.
Mechanical System Integration in Automation:
Collaborate on the integration of robotics, conveyors, indexing systems, vision-guided tools, and mechanical handling equipment.
Ensure mechanical systems support the automation control strategy and sensor placement.
DFM/DFA & Product-Process Alignment:
Influence product designs to ensure ease of mechanical assembly and minimal process variation.
Optimize part orientation, joining methods, and fastener strategies to reduce cycle time and defects.
Structural & Motion Design:
Design robust mechanical structures, load-bearing frames, and motion elements with attention to tolerance stack-up, dynamic loads, and thermal expansion.
Conduct design calculations and FEA where applicable.
Process Optimization & Reliability Engineering:
Evaluate existing mechanical systems for performance, downtime, and quality issues.
Implement design modifications and preventive strategies to enhance MTBF and OEE.
Bachelor’s or Master’s degree in Mechanical Engineering or related discipline.
15+ years of experience in mechanical systems design for manufacturing, assembly, or automation environments.
Proficient in CAD tools (e.g., SolidWorks, CATIA, NX), FEA software, and GD&T standards.
Strong background in machine design, industrial automation, material selection, and mechanical troubleshooting.
Experience with lean manufacturing, Six Sigma, and continuous improvement principles.
Proven track record of leading complex, cross-disciplinary engineering programs from concept to launch.
Exceptional leadership, problem-solving, and communication skills.