Senior Staff Engineer, Advanced Manufacturing

Responsibilities

• Define the Bill of Process and manufacturing sequence for assigned subassemblies or production cells.
• Map MBOMs to operations, tooling requirements, and process controls.
• Build ergonomic workstations with appropriate height/reach zones, shadow boards, calibrated torque tools, ESD controls, and point-of-use materials.
• Create operator-ready work instructions covering 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 First Article Inspection readiness.
• Implement engineering change orders, validate process updates, and maintain work instructions.
• Select and deploy capital equipment and implement hardware, software, and production systems for a new production line.
• Collaborate across engineering, supply chain, production, and quality; mentor other engineers.

Requirements

• 10+ years of experience in manufacturing engineering, production systems, process development, or assembly engineering.
• Bachelor’s degree in Mechanical Engineering, Industrial Engineering, 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 in a fast-paced, high-pressure environment and adapt to changing priorities.

Nice-to-haves

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

Tools and Methods

• MES/QMS systems
• Torque analyzers
• Minitab and Excel for SPC, capability analysis, and DOE
• Lean manufacturing and 5S
• PFMEA
• Ergonomic assessment tools
• Control Plans
• Standard Operating Procedures