Senior Manufacturing / Methods Engineer

Former US Secretary of Energy, Jennifer Granholm said, “With what Virginia Transformer is doing, they are at the center of how we’re going to build out the backbone of our clean energy future.”

Virginia Transformer and Georgia Transformer Corp., is “the engineering firm that makes transformers.”

We are the largest US-owned manufacturer of electric transformers in North America and have been helping to secure the reliability and resilience of our country’s electric grid for more than 50 years. We produce power transformers for any conceivable application – GSU, substations, auto-transformers, grounding transformers, drive duty, rectifier, exciter, voltage regulator, and other.

The company is experiencing steady and sustained growth and serves every part of US industry from its six state-of-the-art North American facilities. We are actively looking for individuals who want to be part of a high-growth company and who want to share in the pride we have in ensuring American manufacturing continues to flourish. Without reliable power, manufacturing cannot operate. That is where we – and you – come in. Join us.

Job Summary:

The Senior Manufacturing / Methods Engineer is responsible for developing, improving, and standardizing manufacturing methods and processes across transformer production operations. This role serves as a technical expert in identifying process inefficiencies, implementing lean practices, and supporting tooling, routings, and work instruction development. The Senior Engineer will work closely with design engineering, production, quality, and maintenance teams to ensure robust, repeatable, and efficient production processes.

Key Responsibilities:

Process Design & Optimization

Develop and refine methods for transformer manufacturing processes including core assembly, coil winding, insulation, tank fabrication, and vacuum pressure drying (VPD).

Lead time studies, workflow analysis, and production line balancing to optimize labor and equipment utilization.

Identify and implement cost-saving opportunities through process improvements, layout changes, or material substitution.

Tooling & Fixtures

Design and implement custom tooling, jigs, and fixtures to improve manufacturability, safety, and quality.

Provide technical support for the setup and use of specialized equipment including winding machines, cranes, air lift systems, and oil processing systems.

Standardization & Documentation

Develop and maintain standard operating procedures (SOPs), work instructions, process flows, and visual aids for production teams.

Create and maintain accurate routings and bills of materials (BOMs) in ERP systems.

Continuous Improvement & Troubleshooting

Lead or support root cause analysis of production issues, quality defects, and process failures.

Support lean manufacturing initiatives (5S, Kaizen, visual management) and drive a culture of continuous improvement.

Serve as a mentor and technical resource for junior engineers and technicians.

New Product & Process Introduction

Collaborate with design and project engineering to ensure new transformer designs are manufacturable and production-ready.

Participate in first article production builds and lead process validation efforts for new products or major design changes.

Qualifications:

Bachelor’s degree in Mechanical, Industrial, or Electrical Engineering.

5+ years of experience in a manufacturing or process engineering role, preferably in electrical equipment or transformer manufacturing.

Strong understanding of manufacturing principles, lean tools, and process analysis techniques.

Proficiency with CAD software (e.g., AutoCAD, Inventor) and familiarity with ERP systems for routings and BOMs.

Hands-on experience with manufacturing tools and systems such as winding machines, VPD ovens, oil processing, and heavy lifting equipment preferred.

Strong problem-solving, communication, and cross-functional collaboration skills.

Travel:

Up to 10% between plant locations as needed for support and implementation.