Design Engineer

The Design Engineer is a detail-oriented and results-driven professional responsible for establishing, maintaining, and sustaining product design from concept through mass production. This role ensures that engineering processes meet required standards through data analysis, problem identification, and solution development.

The Design Engineer plays a critical role in defining and implementing industry best practices, particularly in high-voltage materials and product applications. This position supports the development of reliable, high-performance cable solutions for power systems, military, and industrial automation applications.

As a key member of the Engineering team, the Design Engineer provides subject matter expertise (SME), supports cross-functional collaboration, and drives continuous improvement in design, manufacturing efficiency, and quality assurance.

Key Responsibilities:

Process Development, Standardization & Documentation

*Lead the development and implementation of product standards and engineering best practices.

*Establish and standardize design and development processes to improve consistency, repeatability, and efficiency.

*Develop material and technology methodologies, including application procedures for high-voltage products.

*Ensure all engineering documentation (drawings, specifications, and technical data) aligns with internal, customer, and regulatory requirements.

Design, Analysis & Technical Support

*Investigate and analyze new product concepts and existing product life cycles to drive continuous design improvement.

*Lead root cause analysis, troubleshooting, and implementation of corrective and preventive actions (CAPA).

*Provide technical support for customer applications, new product development, and costing activities.

*Perform electrical and thermal analysis, including voltage drop, ampacity, and related calculations.

Product Development & Validation

*Lead and support prototype builds, testing, and troubleshooting of cable assemblies and high-voltage products.

*Execute and support verification and validation (V&V) activities, including engineering studies and qualification testing.

*Oversee testing including dielectric withstand, insulation resistance, and environmental performance.

*Ensure designs meet manufacturability, performance, reliability, and quality requirements.

Risk Management & Compliance

*Lead and support risk management activities to identify, assess, and mitigate product and process risks.

*Review customer drawings and specifications to ensure compatibility with manufacturing capabilities and standards.

*Ensure compliance with customer, regulatory, and internal Quality Management Systems (ISO, AS9100).

*Drive adherence to applicable industry standards (e.G., IEC, UL, IEEE).

Manufacturing Support & Technical Expertise

*Develop and document manufacturing processes, including machine/fixture design, work instructions, and best practices.

*Troubleshoot production and development issues, implementing solutions to minimize downtime and variability.

*Improve tooling, jigs, and fixtures to enhance efficiency, repeatability, and product quality.

*Partner with production teams to ensure successful implementation of engineering and process improvements.

Continuous Improvement & Operational Excellence

*Lead and support continuous improvement initiatives to drive operational efficiency, quality, and cost reduction.

*Apply Lean and Six Sigma methodologies to improve process capability and consistency.

*Conduct process evaluations, including time and motion studies, to optimize manufacturing performance.

*Collaborate with operators and supervisors to identify improvement opportunities and implement practical solutions.

Quality & Performance Management

*Support and maintain compliance with ISO and AS9100 standards, including document control and audit readiness.

*Drive root cause analysis and CAPA activities to improve first-pass yield and overall product quality.

*Monitor and analyze key performance indicators (KPIs) related to manufacturing efficiency and quality.

*Support internal audits and ensure timely implementation of corrective actions.

*Oversee post-market product performance to ensure quality, reliability, and customer satisfaction.

Cross-Functional Collaboration & Leadership

*Collaborate with Engineering, Quality, Supply Chain, and Production to ensure seamless product lifecycle execution.

*Provide technical leadership, training, and mentorship to engineering and production teams as a subject matter expert (SME).

*Support customer engagement across all phases of the product lifecycle, including design, development, and issue resolution.

*Align engineering and manufacturing initiatives with overall business objectives.

• Bachelor’s degree in manufacturing engineering, industrial engineering, mechanical engineering, electrical engineering or equivalent work experience.
• 3-7+ years of experience in product design, preferably in cable assemblies or high-voltage applications
• Strong background in lean manufacturing, Six Sigma, product development and Design Engineering methodologies.
• Experience in ISO 9001 / AS9100 environments preferred.
• Proficiency in CAD software (AutoCAD, Inventor) and manufacturing process simulation tools.
• Knowledge of root cause analysis techniques (5 Whys, Fishbone, FMEA).
• Strong analytical, problem-solving, and communication skills.
• Excellent communication and collaboration abilities.