Senior Manufacturing Engineer

Hyliion is committed to creating innovative solutions that enable clean, flexible and affordable electricity production. The Company’s primary focus is to develop distributed power generators that can operate on various fuel sources to future-proof against an ever-changing energy economy. Job Purpose The Senior Manufacturing Engineer serves as the senior technical authority for assembly process and equipment design within the Industrialization team. This position designs the assembly lines, fixtures, and material flow systems that convert KARNO prototype and development builds into repeatable, scalable production operations — and then systematically removes waste, labor content, and variation from those operations. Working closely with industrialization leadership, design engineering, production, quality, and supply chain, the Senior Manufacturing Engineer owns the most complex assembly value streams end to end: line and station design, fixture and tooling design, material presentation and handling, process qualification, and continuous waste reduction. This position sets the technical standard for how assembly processes are designed and documented at Hyliion, provides mentorship and design review for other manufacturing engineers, and is accountable for measurable improvement in cycle time, first-pass yield, labor content, and ergonomics across the assembly areas. AI at Hyliion At Hyliion, AI is core to how we work. We equip every team member with leading AI tools and count on you to use them — to move faster, solve harder problems, and help us realize the full potential of KARNO technology for the world. Duties and Responsibilities Assembly Line and Cell Design : Design assembly lines, cells, and workstations for KARNO core, module, and subassembly operations. Establish work sequencing, balance work content to takt, define station layouts and footprints, and design lines that accommodate planned rate increases rather than requiring rebuild to reach them. Fixture, Jig, and Tooling Design : Design assembly and inspection fixtures, jigs, and tooling from concept through qualification. Own datum and locating strategy, tolerance stack-up and GD&T, error-proofing (poka-yoke) features, and fixture qualification including repeatability and gage R&R studies. Review and approve fixture designs produced by other engineers. Material Handling and Flow Optimization : Design material presentation and handling systems that put the right part at the point of use in the right orientation — kitting strategy, cart and rack design, sequencing, kanban and pull loops, and travel distance and motion reduction. Partner with Supply Chain and Production Control on line-side stocking, min/max levels, and WIP control. Waste Reduction in Assembly Operations : Systematically identify and eliminate waste across assembly operations — motion, waiting, rework, overprocessing, transport, and excess inventory. Reduce labor content and cycle time per unit through standard work, work sequencing, changeover reduction, error-proofing, and station design. Quantify the value of each change before implementation and verify the result afterward. Prototype Development and Production Scaling : Collaborate with design engineering to develop prototype build processes and transition them to efficient, repeatable production-scale operations, including cross-site process transfer between the Milford, OH and Cedar Park, TX facilities. Process Development and Optimization : Design, develop, implement, and qualify manufacturing processes for engine, generator, electric machine, and precision electromechanical assembly operations, including processes involving high-voltage systems, sealed pressure systems, and additively manufactured components. Process Documentation and Control : Author and maintain the process documentation set — PFMEAs, control plans, work instructions, travelers, and routings — and ensure the manufacturing BOM structure reflects how the product is actually built. Verify on the floor that the documented process is the process being followed. Technical Leadership and Mentorship : Serve as the subject matter expert for assembly process and fixture design. Provide technical guidance to production teams, mentor and develop manufacturing engineers and technicians, lead design reviews, and represent Manufacturing Engineering in engineering design reviews with the standing to influence design for manufacturability and hold configuration stability. Capital Equipment and Automation : Specify, justify, procure, install, and qualify capital equipment, semi-automated assembly aids, and material handling equipment. Build the business case, run the vendor selection, and own installation and process qualification through to validated production use. Additive Manufacturing : Integrate additive manufacturing technologies into production processes where applicable, including design and process considerations specific to additively manufactured assemblies. Problem-Solving and Root Cause Analysis : Lead root cause analysis and corrective action for assembly process and quality issues using 5-Why, 8D, DOE, and statistical methods. Drive corrective actions to verified closure rather than disposition. Project Management : Manage cross-functional industrialization projects, ensuring timelines, budgets, and objectives are met, and escalating early with a recommendation attached. Safety and Ergonomics : Design workstations, fixtures, and material handling that support safe work — reach, lift, posture, tool access, and energy control. Participate actively in hazard identification, near-miss reporting, and LOTO and electrical safety discipline. Additional duties and responsibilities as assigned, needed, or required for the business. Qualifications Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions. Qualifications include: Education, Exp