Senior Mechanical and Automation Engineer at Hydranautics - A Nitto Group Company in Oceanside, CA, USA

Job description

• Under the general supervision of the Engineering Director, the 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. The incumbent operates in a challenging manufacturing environment characterized by unstructured legacy processes, outdated documentation, heavy manual handling operations, and budget and safety constraints that demand creative engineering solutions.

Responsibilities

• ESSENTIAL DUTIES and/or RESPONSIBILITIES: Design, develop, and commission mechanical and automated equipment to eliminate manual heavy-handling operations in membrane manufacturing; apply DFM and DFS principles to produce safe, cost-effective, and maintainable solutions within defined capital budget constraints.
• 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.
• This position leads small project teams of 2–5 engineers, technicians, or contractors on a project basis. No direct supervisory authority over permanent headcount.

Requirements

• 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.
• Expert-level mechanical design proficiency using 3D CAD software (SolidWorks, AutoCAD, or equivalent); ability to produce and manage engineering drawings, GD&T specifications, tolerancing analysis, and BOM documentation for complex mechanical assemblies and automated systems.
• Hands-on electrical and controls engineering competency: panel wiring, PLC programming (Allen Bradley/Rockwell, Siemens, or equivalent), HMI configuration, servo and stepper drive commissioning, pneumatic system design, and sensor/vision system integration.
• Advanced mastery of FMEA methodologies: ability to independently lead and facilitate Process FMEA (PFMEA), Machine FMEA, and Assembly FMEA sessions; assign Severity, Occurrence, and Detection ratings; calculate RPN scores; prioritize and drive risk mitigation actions to defined target thresholds before production release.
• Expert application of Poka Yoke (mistake-proofing) design principles: fixture-based error-proofing, sensor-based detection and rejection interlocks, visual management and color-coding systems, and assembly verification mechanisms to prevent defect escape in membrane manufacturing operations.
• Proficiency in Control Plan development and ongoing governance: linking PFMEA outputs to process control parameters, measurement system requirements, inspection frequency, reaction plans, and SPC monitoring triggers; ability to train operators and technicians on Control Plan requirements.
• Strong working knowledge of Lean Manufacturing and Six Sigma tools including VSM, DMAIC, FMEA, 5S, SMED, and Kaizen facilitation; Six Sigma Green Belt certification or equivalent applied project experience required.
• Demonstrated ability to develop, formalize, and govern engineering documentation in legacy or underdeveloped environments: SOPs, work instructions, process flow diagrams, engineering change orders, and equipment qualification and validation records.
• Read and comprehend highly complex engineering specifications, regulatory standards, and technical documentation; write technical reports, engineering proposals, and capital justifications; effectively present recommendations to cross-functional stakeholders and management in one-on-one and group settings.
• Strong project management skills: ability to manage multiple concurrent engineering projects, vendor relationships, and contractor activities within approved budget and schedule; proficiency in MS Project or equivalent project management tools.
• Advanced Microsoft Office Suite skills (Word, Excel, PowerPoint, Outlook); working knowledge of ERP/MRP systems (JD Edwards or equivalent) for materials planning, requisition management, and project cost tracking.
• Six Sigma Green Belt (required); Black Belt preferred. OSHA 30-Hour General Industry certification preferred. PLC Programming certification (Allen Bradley/Rockwell or Siemens equivalent) preferred.

Skills

Preferred

• Six Sigma Black Belt

Benefits

• We are proud to offer a generous compensation and robust benefits package to include medical, dental, vision, life insurance plans, F.S.A. and H.S.A plans, Retirement plans (401k and ROTH), (12) Paid company holidays, generous PTO, tuition reimbursement and career development, Employee Assistance Plan, and more. This is an onsite position in our Oceanside, CA facility.
• Email Me Similar Jobs
• Email Me This Job
• We are proud to offer a generous compensation and robust benefits package to include medical, dental, vision, life insurance plans, F.S.A. and H.S.A plans, Retirement plans (401k and ROTH), (12) Paid company holidays, generous PTO, tuition reimbursement and career development, Employee Assistance Plan, and more. This is an onsite position in our Oceanside, CA facility.