# Senior Staff Engineer, Advanced Manufacturing (R4359)

**Company:** [Shield AI](https://hotfix.jobs/companies/shield-ai)
**Location:** Dallas, TX
**Role:** Hardware Engineering
**Salary:** $150k – $230k/yr
**Experience:** 7+ years
**Skills:** Mes, Qms, Minitab, Excel, Lean, 5S, Pfmea, CAD, Torque Analyzers, Control Plans, Spc, Doe, Kaizen, As9100, Iso 9001
**Posted:** 2026-01-13

> Develops manufacturing processes, ergonomic workstations, and work instructions for aerospace assemblies to drive production stability and rate acceleration. Requires 7+ years in manufacturing engineering, bachelor's in STEM, and experience with prototype production in fast-paced environments.

## Job Description

## Responsibilities
- Define the Bill of Process and manufacturing sequence for assigned subassemblies or cells.
- Map MBOM to operations, tooling needs, and process controls.
- Build ergonomic workstations (height/reach zones, shadow boards, calibrated torque tools, ESD controls, POU materials).
- Create visual, operator-ready Work Instructions with torque specs, PPE, inspection points, and MES revision control.
- Conduct time studies, compute takt/CT, identify bottlenecks, and lead kaizen improvements.
- Establish standardized work, visual controls, job aids, and layered audit systems; iterate with operators.
- Capture shop-floor lessons learned defects, build issues, tooling feedback and drive root cause and corrective action.
- Partner with Quality on in-process checks, error-proofing, and FAI readiness.
- Implement ECOs, validate process updates, and maintain work instructions accordingly.

## Required Qualifications
- 7+ years of experience in manufacturing engineering, production systems, process development, or assembly engineering.
- Bachelor’s degree in Mechanical, Industrial, Mechatronics, or related STEM field.
- Experience in prototype manufacturing in a startup or rapid-growth environment.
- Strong understanding of manufacturing processes, including machining, composites, avionics and/or assembly.
- Demonstrated ability to work in a fast-paced, high-pressure environment and adapt to changing priorities.

## Preferred Qualifications
- Knowledge of quality standards, such as **AS9100** or **ISO 9001**.
- Proficiency in **CAD software**.
- Familiarity with advanced manufacturing technologies, such as additive manufacturing or automation systems.
- Hands-on experience with manufacturing equipment and tooling design.
- Strong project management skills, including experience managing multiple priorities and deadlines.

## Tools & Skills
- **MES/QMS systems**
- **Torque analyzers**
- **Minitab/Excel** (SPC, capability, DOE)
- **Lean/5S**
- **PFMEA**
- **Ergonomic assessment tools**
- **Control Plans**
- **Standard Operating Procedures**

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**Canonical:** https://hotfix.jobs/jobs/df856eb2-ef7b-41b3-88f0-a56e5ff3ecb9