KKR Consulting partners with businesses to solve challenges, streamline processes, and achieve lasting success. We specialize in providing tailored consulting services across Aerospace, Medical Devices, Automotives, Pharmaceuticals, and Biotechnology industries, helping clients drive innovation, enhance operations, and achieve sustainable growth.
Title: Manufacturing Engineer
Location: Burlington, MA (Onsite)
Description:
The Senior Manufacturing Engineer will work cross-functionally to deliver safe, efficient processes that meet quality, cost, capacity, and customer requirements. This role will work cross-functionally on NPI teams to support process development and help successfully sample and launch new products. This role will also be responsible for taking new products from post-print to finished product by developing and scaling robust post-processing operations. They will provide technical leadership for the Production Team, define process requirements, coordinate with suppliers, and implement tooling and equipment solutions for post-processing printed parts and components.
Key Responsibilities:
- Define and support the design of subtractive post-processing steps (e.g., machining, blasting, deburring) for new product introductions; turn product designs and requirements into robust, scalable manufacturing processes.
- Oversee the implementation of subtractive manufacturing processes by collaborating with in-house technicians and external suppliers. Coordinate machine setup and process validation while maintaining technical ownership.
- Define functional requirements for tooling, fixturing, and post-processing equipment, including identifying opportunities for automation or capital investment to improve productivity. Partner with suppliers to deliver reliable solutions, and lead their implementation, testing, and validation.
- Write and maintain detailed work instructions, standard operating procedures (SOPs), and process documentation to ensure repeatable and high-quality production.
- Lead Installation Qualifications (IQ) for manufacturing equipment and support QC and Quality Engineering in Operational and Performance Qualifications (OQ/PQ). Help ensure all processes meet quality and regulatory requirements.
- Engage early in the NPI process to understand part requirements and contribute to design-for-manufacturability (DFM) decisions. Work closely with design, quality, and production teams to align on cost, capability, and scalability.
- Collaborate with product and manufacturing teams to define takt time, throughput targets, and resource needs (equipment, labor, space) to support forecasted production volumes – including estimating manufacturing costs and time standards for new and existing products.
- Work with the HSSE team to assess risks and ensure that new equipment and processes meet internal safety and ergonomic standards.
- Drive process improvements aimed at scrap reduction and cost savings using root cause analysis, lean tools and data-driven decision making.
Qualifications:
- 5+ years of experience in manufacturing engineering, with a focus on post-processing and/or subtractive methods (e.g., machining, blasting, fixturing)
- Work on NPI products & process development, cross-functional teams
- Hands-on experience developing and scaling production processes, including working with CNC equipment and subtractive manufacturing techniques
- Proficiency in process qualification tools and methods (e.g., PFMEA, DOE, IQ/OQ/PQ)
- Strong cross-functional collaboration skills, including working with suppliers, technicians, and internal engineering, quality, and production teams
- Experience creating and maintaining process documentation (e.g., SOPs, work instructions, validation plans)
- Knowledge of Lean Manufacturing, root cause analysis, and continuous improvement methods
Preferred
- Experience with metal additive manufacturing and transitioning printed parts to finished product
- Familiarity with subtractive manufacturing principles, GD&T, and tooling/fixturing design
- Background in regulated or quality-controlled environments (e.g., medical device, aerospace) and experience qualifying equipment or automated processes
- Exposure to ERP/MES systems, manufacturing data tools, and safety or ergonomic assessments
- Degree: Bachelor’s degree in Mechanical, Manufacturing, or Industrial Engineering (or related field)
Benefits:
- Medical insurance
- Vision insurance
- Dental insurance
- 401(k)
