Staff Engineer, Advanced Manufacturing - Special Projects (R4972)

What you'll do

• 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

Tools & Skills

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

Required Qualifications

• Ability to obtain and maintain a 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 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