The Senior Expert Factory Engineer is responsible for leading the design, optimization, and continuous improvement of complex manufacturing systems that integrate people, technology, materials, information, and processes.
The role provides advanced expertise in process engineering, Lean methodologies, operational excellence, and data-driven improvement to increase productivity, quality, flexibility, and cost efficiency across the plant. The Expert Factory Engineer also drives the standardization and replication of best practices within the PowerCo plant network.
1. Technical Leadership & Manufacturing Excellence
• Define and continuously develop technical standards, methodologies, and best practices for manufacturing system design and optimization.
• Lead complex, high-impact improvement initiatives with significant implications for productivity, capacity, cost, quality, and operational performance.
• Challenge existing processes, manufacturing concepts, and technical assumptions to identify opportunities for breakthrough improvements.
• Provide technical direction and expert support to engineering and operational teams across the organization.
• Drive independently the continuous evolution and application of the PowerCo Excellence System, including Lean, Six Sigma, Kaizen, Problem Solving, Quick Setup, Shopfloor Management, and related methodologies.
• Decide measures to optimize the production flow and output.
• Steer optimization workshops
2. Advanced Manufacturing Systems & Industrial Engineering
• Lead the design and optimization of complex manufacturing systems integrating people, equipment, automation, material flows, information systems, and operational processes.
• Define advanced methodologies for capacity planning, workforce modelling, line balancing, process optimization, resource utilization, and productivity analysis.
• Lead complex capacity and production system studies to support strategic decisions regarding production volumes, equipment requirements, staffing, and future manufacturing expansion.
• Identify and resolve systemic constraints, bottlenecks, and performance losses across the end-to-end manufacturing process.
• Support critical industrialization, ramp-up, and transformation projects by ensuring robust, scalable, and efficient production concepts.
• Define and standardize Industrial Engineering methodologies across the PowerCo manufacturing network.
3. Strategic Factory Planning & System Design
• Translate long-term business, production, and technological requirements into sustainable and scalable manufacturing strategies.
• Lead the technical evaluation of alternative manufacturing concepts, production scenarios, and operational strategies.
• Support strategic decisions related to capacity expansion, CAPEX investments, automation concepts, workforce strategies, and manufacturing footprint.
• Develop future-state manufacturing concepts and roadmaps aligned with PowerCo's long-term industrial strategy.
• Evaluate the scalability and replicability of manufacturing solutions across different plants and production environments.
• Identify and lead opportunities to standardize successful technical solutions across the PowerCo production network.
4. Data-Driven Engineering & Advanced Analytics
• Define the analytical framework and relevant KPIs required to evaluate manufacturing system performance and support strategic decision-making.
• Lead complex analysis of operational and engineering data to identify systemic trends, constraints, root causes, and improvement opportunities.
• Establish robust performance baselines and methodologies to quantify the technical and financial impact of improvement initiatives.
• Drive the development and implementation of advanced digital tools for manufacturing analysis and process optimization.
• Promote the use of digital Value Stream Mapping, advanced analytics, modelling, and simulation to support fact-based engineering decisions.
• Ensure that engineering recommendations are supported by robust data, analysis, and technical evidence.
5. Operational Performance & Cost Optimization
• Identify and lead high-impact opportunities to improve productivity and reduce manufacturing costs while maintaining safety, quality, compliance, and operational requirements.
• Develop and implement strategies to optimize workforce utilization, equipment performance, material flows, and overall resource efficiency.
• Evaluate the full business impact of engineering solutions, including CAPEX, OPEX, productivity, cost per unit, and return on investment.
• Support management in prioritizing improvement initiatives based on technical feasibility, business impact, implementation risk, and strategic relevance.
• Drive sustainable improvements and ensure that implemented solutions deliver measurable and lasting results.
6. Network Standardization & Knowledge Leadership
• Lead the identification, development, and deployment of best practices across the PowerCo manufacturing network.
• Establish common Factory Engineering and Industrial Engineering standards to ensure consistency and scalability across plants.
• Benchmark manufacturing performance and engineering practices across PowerCo sites and identify opportunities for cross-site improvement.
• Coordinate with PowerCo Headquarters in Salzgitter and other plants, including St. Thomas, to align methodologies, technical strategies, and operational standards.
• Lead cross-functional and international technical communities or working groups in areas of expertise.
• Drive knowledge transfer between plants and support the implementation of standardized solutions.
7. Stakeholder Management & Capability Development
• Act as a trusted technical advisor to plant leadership, engineering management, and key operational stakeholders.
• Influence strategic and operational decisions through robust technical analysis and evidence-based recommendations.
• Lead cross-functional initiatives involving Production, Maintenance, Quality, Logistics, Supply Chain, Automation, and Engineering.
• Communicate complex technical concepts and recommendations clearly to both technical and non-technical stakeholders.
• Mentor and coach Industrial Engineers and other technical specialists, supporting the development of organizational capabilities.
• Contribute to the development of technical talent, methodologies, and succession capabilities within Factory Engineering.
