Staff Engineer, Advanced Manufacturing - Special Projects

Responsibilities

• Own critical manufacturing processes across multiple programs, leading initiatives to increase throughput, reduce costs, and scale operations.
• Build infrastructure for a new production line supporting a next-generation jet, including selecting and deploying capital equipment, implementing hardware and software tools, and establishing production systems.
• Define the Bill of Process and manufacturing sequence for assigned subassemblies or cells.
• Map MBOMs to operations, tooling needs, and process controls.
• Build ergonomic workstations with height/reach zones, shadow boards, calibrated torque tools, ESD controls, and point-of-use materials.
• Create operator-ready work instructions with torque specifications, PPE, inspection points, and MES revision control.
• Conduct time studies, calculate takt time and cycle time, identify bottlenecks, and lead kaizen improvements.
• Establish standardized work, visual controls, job aids, and layered audit systems in collaboration with operators.
• Capture shop-floor lessons learned, defects, build issues, and tooling feedback; drive root-cause analysis and corrective action.
• Partner with Quality on in-process checks, error-proofing, and FAI readiness.
• Implement ECOs, validate process updates, and maintain work instructions.
• Collaborate across engineering, supply chain, production, and quality; mentor other engineers.

Required Qualifications

• Current Top Secret clearance.
• 7+ years of experience in manufacturing engineering, production systems, process development, or assembly engineering.
• Bachelor's degree in Mechanical, Industrial, Mechatronics, or a related STEM field.
• Experience in prototype manufacturing within a startup or rapid-growth environment.
• Strong understanding of manufacturing processes, including machining, composites, avionics, and/or assembly.
• Ability to work effectively in a fast-paced, high-pressure environment and adapt to changing priorities.

Preferred Qualifications

• Knowledge of AS9100 or ISO 9001 quality standards.
• Proficiency with CAD software.
• Familiarity with additive manufacturing or automation systems.
• Hands-on experience with manufacturing equipment and tooling design.
• Strong project management skills, including managing multiple priorities and deadlines.

Tools and Methods

• MES/QMS systems
• Torque analyzers
• Minitab
• Microsoft Excel
• Statistical process control (SPC)
• Capability analysis
• Design of experiments (DOE)
• Lean manufacturing
• 5S
• PFMEA
• Ergonomic assessment tools
• Control Plans
• Standard Operating Procedures (SOPs)