What to Look For in a Process / Manufacturing Engineer: Advice for Hardtech Startups

June 25, 2022

In the early stages of a technical start-up, the process of assembling the right team can have a lasting impact on the success of a company.  Team members not only shape the company’s culture and identity, but also play significant roles in demonstrating the technical and commercial viability of the breakthrough technology.  

Maturing a technology from a scientific journal article to a scalable, reproducible manufacturing process is a journey that can take years of experimentation and learning.  Often, this work is enabled by early investor funding.  Once committed to its targets, the company races against time to deliver significant improvements in performance, scale, and cost over what was previously done on a laboratory bench.  It is paramount that the company sets itself up to maximize its chance of success in the shortest amount of time by learning strategically and efficiently, and then leveraging its growing knowledge base to iterate and improve its processes.  

To quote an age-old adage, “go slow to go fast”. A methodical, quantitative approach to problem-solving will deliver robust progress faster than an whack-a-mole, trial-and-error approach.

The process engineer / manufacturing engineer (the titles are often interchangeable) is the key player in product and process development.  A question that often comes up during hiring is whether more emphasis should be placed on knowledge in the niche scientific expertise, or general knowledge in the field of manufacturing engineering. 

• A Strong Foundation Comes First

The “depth” vs. “breadth” trade-off is not a either/or question - a mix of both is ideal. However, it is likely easier and faster for someone to learn about the core science behind the innovation, than to master the breadth of manufacturing engineering concepts and skills.  To hit the ground running, I recommend looking for someone who has industry experience and is already confident applying these concepts and methods.  With the tools already under their belt, the candidate would be well-equipped to solve technical problems and navigate the associated uncertainty.

• Link Your Needs to Specific Skills and Ask for Them

There is a vast body of knowledge in the field of process/manufacturing engineering.  Lean (focused on reducing waste) and Six Sigma (focused on reducing variations) are two complementary approaches that are widely practiced in process development, manufacturing, and operations. For enterprise leaders who are beginning to get familiar with manufacturing,  the abundance of jargon can seem daunting.  Below is a list of frequently used terms, grouped by high-level objectives that the engineer may take on.

It is our hope that the table below will help to bring innovation-driven companies closer to finding and recruiting ideal candidates to jump-start their scale-up efforts. A well-rounded, capable process/manufacturing engineer can dramatically accelerate operational growth and help the company deliver value to their customers sooner.  When done with intention, a great process / manufacturing engineer hire will continuously propel the company to new heights.

If you want someone who can…	Use these keywords in the job description Look for them in the resume Ask about them during the interview
Analyze quantitative data to draw conclusions	Six Sigma Green Belt or Black belt DMAIC method Minitab Measurement System Analysis Gauge R&R Regression ANOVA Hypothesis testing
Design and perform experiments to systematically optimize process parameters	Design of Experiment (DOE) Factors Levels Responses
Assess the ability of a process to meet customer specifications	Voice of the customer Specification limits Process capability Critical to Quality (CTQ)
Identify, prioritize,and mitigate process risks	Process Risk Analysis Process Mapping Cause and Effect Matrix Process Failure Mode and Effects Analysis (pFMEA) Control Plans
Monitor process and distinguish between common cause vs. special cause variations	Voice of the process Statistical Process Control (SPC) Common causes vs Special causes Control limits Rational subgrouping
Think at system-level and build consensus	A3 problem solving Plan-Do-Check-Act (PDCA) Policy Deployment (Hoshin Kanri)
Train others to do hands-on operations effectively	Training Within Industry (TWI) Job Instruction Work Instructions / SOP
Have a strong understanding of Lean concepts	5S (or 6S) Continuous Improvement (kaizen) Mistake-proofing (poka-yoke) Value Stream Maps First In First Out (FIFO) Kanban Standardized work
Reorder, inspect, and receive raw materials	Incoming inspection Inspection criteria Critical to Quality (CTQ)
Specify, purchase, and install equipment	Installation Qualification (IQ), Operational Qualification (OQ), Performance Qualification (PQ)*
Oversee and maintain equipment	Preventive Maintenance (PM) Calibration
Design custom fixtures	Mechanical engineering knowledge Engineering Drawings Geometric Dimensioning and Tolerancing (GD&T) Computer Aided Design (CAD) experience [popular softwares include Solidworks, Fusion360, Onshape, AutoCAD] Design for Manufacturability
Fabricate custom fixtures	3D printing Basic machining

*IQ/OQ/PQ is used in highly regulated industries - it may be excessive at an early stage, but is a good benchmark.