Powell Industries
Powell Research and Development is hiring a Senior Design for Manufacture (DFM) Engineer in Southeast Houston. This role is intentionally designed to recognize either formal engineering education with experience OR extensive hands‑on CNC machining expertise as equally valuable pathways to success.
As a Senior DFM Engineer, you will be a core member of the Research and Development Team, working alongside New Product Development Engineers, Manufacturing Engineers, and production teams to ensure new designs are manufacturable, cost‑effective, and production‑ready. This position bridges design intent and shop‑floor reality and plays a critical role in scaling designs from prototype to full production. This position does not allow for sponsorship support.
Job Description
Collaborate with cross‑functional engineering, manufacturing, and machining teams to ensure robust DFM/DFA/DFX throughout the product lifecycle.
Review parts and assemblies with a strong focus on machinability, tolerancing, fixturing, tooling access, and assembly efficiency.
Identify manufacturability, machining, and assembly risks early and provide clear, actionable design recommendations.
Translate design intent into practical, repeatable manufacturing solutions, informed by real‑world machining capability.
Ensure product manufacturing and assembly requirements are clearly understood by production teams.
Support new product development by evaluating and improving machining methods, tooling strategies, fixtures, and work holding concepts.
Improve manufacturing efficiency by helping to analyze and plan workflow, space requirements, and equipment layout.
Assure product and process quality by helping to design testing methods; testing finished‑product and process capabilities; establishing standards; confirming manufacturing processes.
Provide upfront input into prototype and production designs, including machining time, labor estimates, tooling cost, and material selection.
Support development of work instructions, machining standards, and best practices.
Serve as a technical resource for manufacturability and machining feasibility questions.
Train and support manufacturing and assembly personnel as needed.
Contribute to continuous improvement initiatives and cross‑functional problem solving.
Minimum Qualifications – Two Equivalent Pathways Path A: Engineering Degree + Experience
Bachelor’s degree in Manufacturing Engineering, Mechanical Engineering, or related field
Minimum 8–10 years of experience in manufacturing engineering, DFM/DFA, or related roles
Demonstrated success applying DFM principles in a production environment
Path B: CNC Machining Experience (No Degree Required)
Minimum 10–15+ years of progressive CNC machining experience in a production and/or prototype environment (20+ years strongly preferred)
Proven track record as a senior‑level CNC machinist with deep understanding of:
CNC and manual milling and lathe
Complex setups, fixturing, and work holding
Tolerance stack‑ups and process capability
Tooling selection and machining strategy
Demonstrated experience contributing to design‑for‑manufacture decisions, including recommending design changes to improve machinability, cost, and quality
Ability to function as a technical authority across machining and manufacturing teams
Note: Candidates qualifying through either pathway are considered equal for this role. This position values applied manufacturing expertise on the same level as formal engineering education.
Job Requirements
Strong understanding of DFM/DFA principles
Solid knowledge of sheet metal design, including self‑fixturing concepts
Ability to interpret and influence CAD models and engineering drawings
Autodesk Inventor experience preferred; CAD proficiency required regardless of pathway
Working knowledge of CNC programming strategies (e.g., Mastercam or similar CAM systems)
Strong mechanical aptitude with understanding of:
Pneumatic, hydraulic, and servo systems
Machine controls and automation
Familiarity with statistical test procedures and corrective action techniques
Strong problem‑solving and analytical skills
Effective written and verbal communication skills, especially between engineering and shop‑floor teams
Ability to manage multiple priorities and drive work to completion
Self‑motivated, adaptable, and comfortable leading change
Working Conditions The employee typically performs duties in a normal office environment. There may be some work in a manufacturing environment and exposure to the elements of our factory. Additionally, there may be some work performed in the field with exposure to construction sites or active customer facilities. It is the policy of Powell Industries to promote safe working conditions for ALL employees, to make available where necessary special equipment to protect employees against specific hazards, to reduce accidents through prevention programs, and to establish rules that are designed for the safety of all. It is the responsibility of each employee to adhere to this policy, as well as to observe all safety practices and exercise every precaution for the safety of accidents. This position is expected to travel 5‑10% of the time and must be able to travel with short notice and/or for extended periods.
Physical Requirements
Regularly required to use hands to touch, hold, handle, or feel
Frequently required to stand, sit, walk and reach with hands and arms; stoop kneel, crouch, or crawl; and talk or hear
Must occasionally lift and/or move up to 65 pounds
Maintaining body equilibrium and agility to prevent falling when walking, standing, crouching, ascending, or descending stairs
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As a Senior DFM Engineer, you will be a core member of the Research and Development Team, working alongside New Product Development Engineers, Manufacturing Engineers, and production teams to ensure new designs are manufacturable, cost‑effective, and production‑ready. This position bridges design intent and shop‑floor reality and plays a critical role in scaling designs from prototype to full production. This position does not allow for sponsorship support.
Job Description
Collaborate with cross‑functional engineering, manufacturing, and machining teams to ensure robust DFM/DFA/DFX throughout the product lifecycle.
Review parts and assemblies with a strong focus on machinability, tolerancing, fixturing, tooling access, and assembly efficiency.
Identify manufacturability, machining, and assembly risks early and provide clear, actionable design recommendations.
Translate design intent into practical, repeatable manufacturing solutions, informed by real‑world machining capability.
Ensure product manufacturing and assembly requirements are clearly understood by production teams.
Support new product development by evaluating and improving machining methods, tooling strategies, fixtures, and work holding concepts.
Improve manufacturing efficiency by helping to analyze and plan workflow, space requirements, and equipment layout.
Assure product and process quality by helping to design testing methods; testing finished‑product and process capabilities; establishing standards; confirming manufacturing processes.
Provide upfront input into prototype and production designs, including machining time, labor estimates, tooling cost, and material selection.
Support development of work instructions, machining standards, and best practices.
Serve as a technical resource for manufacturability and machining feasibility questions.
Train and support manufacturing and assembly personnel as needed.
Contribute to continuous improvement initiatives and cross‑functional problem solving.
Minimum Qualifications – Two Equivalent Pathways Path A: Engineering Degree + Experience
Bachelor’s degree in Manufacturing Engineering, Mechanical Engineering, or related field
Minimum 8–10 years of experience in manufacturing engineering, DFM/DFA, or related roles
Demonstrated success applying DFM principles in a production environment
Path B: CNC Machining Experience (No Degree Required)
Minimum 10–15+ years of progressive CNC machining experience in a production and/or prototype environment (20+ years strongly preferred)
Proven track record as a senior‑level CNC machinist with deep understanding of:
CNC and manual milling and lathe
Complex setups, fixturing, and work holding
Tolerance stack‑ups and process capability
Tooling selection and machining strategy
Demonstrated experience contributing to design‑for‑manufacture decisions, including recommending design changes to improve machinability, cost, and quality
Ability to function as a technical authority across machining and manufacturing teams
Note: Candidates qualifying through either pathway are considered equal for this role. This position values applied manufacturing expertise on the same level as formal engineering education.
Job Requirements
Strong understanding of DFM/DFA principles
Solid knowledge of sheet metal design, including self‑fixturing concepts
Ability to interpret and influence CAD models and engineering drawings
Autodesk Inventor experience preferred; CAD proficiency required regardless of pathway
Working knowledge of CNC programming strategies (e.g., Mastercam or similar CAM systems)
Strong mechanical aptitude with understanding of:
Pneumatic, hydraulic, and servo systems
Machine controls and automation
Familiarity with statistical test procedures and corrective action techniques
Strong problem‑solving and analytical skills
Effective written and verbal communication skills, especially between engineering and shop‑floor teams
Ability to manage multiple priorities and drive work to completion
Self‑motivated, adaptable, and comfortable leading change
Working Conditions The employee typically performs duties in a normal office environment. There may be some work in a manufacturing environment and exposure to the elements of our factory. Additionally, there may be some work performed in the field with exposure to construction sites or active customer facilities. It is the policy of Powell Industries to promote safe working conditions for ALL employees, to make available where necessary special equipment to protect employees against specific hazards, to reduce accidents through prevention programs, and to establish rules that are designed for the safety of all. It is the responsibility of each employee to adhere to this policy, as well as to observe all safety practices and exercise every precaution for the safety of accidents. This position is expected to travel 5‑10% of the time and must be able to travel with short notice and/or for extended periods.
Physical Requirements
Regularly required to use hands to touch, hold, handle, or feel
Frequently required to stand, sit, walk and reach with hands and arms; stoop kneel, crouch, or crawl; and talk or hear
Must occasionally lift and/or move up to 65 pounds
Maintaining body equilibrium and agility to prevent falling when walking, standing, crouching, ascending, or descending stairs
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