Senior / Staff Manufacturing Engineer (NPI)

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Waabi, founded by AI visionary Raquel Urtasun, is the leader in Physical AI. With a world-class team, we're unlocking the next era of autonomous transportation with technology that's powering commercial autonomous trucks and robotaxis. Waabi is backed by and partners with world leaders in AI, automotive, logistics, and deep tech.
With offices in Toronto, San Francisco, Dallas, and Pittsburgh, Waabi is growing quickly and looking for diverse, innovative and collaborative candidates who want to impact the world in a positive way. To learn more visit: www.waabi.ai

You will...
Drive APQP Program Management at CM/Tier 1 sites, owning APQP to ensure a flawless Start of Production (SOP) and obtain PPAP deliverables.
Design for Manufacturing (DFM) & Assembly (DFA): Provide design maturity feedback during APQP Phase 2, ensuring that the hardware can be built repeatedly with the CM’s specific tooling and equipment.
Support Supplier Quality Engineering (SQE) by validating that component-level PPAPs from sub-tier vendors are integrated correctly into the CM’s assembly process.
Be responsible for the mechanical assembly, test, and integration of sensors, compute, and actuation systems, defining the special characteristic (SC/CC) steps for the manufacturing process.
Work closely with cross-functional teams to define, deploy, and validate End-of-Line (EOL) testers and calibration routines that confirm the "digital health" of the hardware.
Lead the development of Process PPAP deliverables, including PFMEAs, Process Flow Diagrams, Control Plans, and Work Instructions ensuring the CM has identified and mitigated all assembly-related risks with "Poka-Yoke" (error-proofing) solution, and has established a robust manufacturing process.
Design and qualify manufacturing equipment, tooling and gauges, ensuring that manufacturing process controls are in place. Providing assurance that GD&T and/or general specification and tolerance requirements are consistently met through MSA (Measurement Systems Analysis) and Gage R&R.
Support Process Verification (PV) Testing, conducting "Run-at-Rate" studies to prove the manufacturing line can sustain quality targets at full production speed.
Lead internal and CM-based RCCA (Root Cause Corrective Action) using the 8D methodology to resolve technical assembly failures during manufacturing.
Manage Metrology and Measurement Systems Analysis (MSA), ensuring that all gauges and inspection fixtures at the CM are qualified via Gage R&R before production use.
Collaborate with Field Quality teams to update manufacturing Control Plans based on real-world performance data and feedback from OEM partners.

Qualifications:
Bachelors of Science in Mechanical Engineering or similar fields.
NPI & CM Oversight Experience: Proven track record of launching automotive or high-tech hardware at Tier 1 or Contract Manufacturers using structured quality gates.
Technical ownership of the launch cycle, specifically focusing on the transition from prototype to a production-validated manufacturing line.
Advanced APQP & PPAP Management: Mastery of Control Plans, Process Flows, and Gage R&R, with a specific focus on manufacturing process stability (Cpk). Experience managing the transition from Design Verification (DV) to Process Verification (PV) and overseeing full PPAP submissions for complex electromechanical systems.
Proficient with Solidworks for reviewing assembly fixtures, pallets, and inspection jigs.
Expertise in GD&T & Metrology: Deep understanding of how to verify complex mechanical tolerances in a production environment using CMM, OMM, or vision systems.
Problem-Solving Expert: Mastery of 8D and RCCA, with the ability to lead high-pressure technical resolution activities during a production ramp.
Experience with PLM tools and document revision control to manage Engineering Change Orders (ECOs) and ensure BOM accuracy during the APQP cycle.
Experience with various manufacturing processes such as precision torque, thermal interface material (TIM) dispensing, and high-stakes sensor calibration.
Present manufacturing readiness to cross-functional teams, using data-driven insights to justify the move from APQP Phase 3 to Phase 4.

Bonus Qualifications:
Automotive, Aerospace, Autonomous Vehicle (AV) or EV industry experience is highly preferred.
IPC/WHMA-A-620 and IPC-A-610 knowledge for acceptance of wire harness assemblies and electronic assemblies.
Experience with Robotic Workcells or automated assembly systems.
Certified Quality Engineer (CQE) or Six Sigma Green/Black Belt.

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