Manufacturing Engineer (Composite)

SUMMARY

The Manufacturing Engineer supports the optimization, improvement, and scalability of composite aerospace manufacturing operations. This position evaluates production processes, identifies opportunities to improve efficiency, quality, and cost performance, and implements process improvements across composite fabrication, assembly, and inspection operations. The Manufacturing Engineer partners with Operations, Quality, Supply Chain, and Engineering to improve manufacturability, eliminate production bottlenecks, support production readiness, and ensure compliance with aerospace quality and regulatory requirements.

ESSENTIAL FUNCTIONS

• Evaluates existing composite manufacturing processes and identifies opportunities to improve throughput, yield, quality, and cost performance.
• Analyzes production workflows, cycle times, labor utilization, and equipment effectiveness to eliminate waste and improve operational efficiency.
• Develops and implements manufacturing process improvements for composite layup, curing, trimming, machining, bonding, assembly, and inspection operations.
• Leads root cause investigations and implements corrective actions related to production defects, nonconformances, scrap, and rework.
• Creates, revises, and maintains manufacturing work instructions, process specifications, standard operating procedures, and production documentation.
• Supports tooling, fixture, and equipment improvements to enhance manufacturability, repeatability, and production efficiency.
• Applies Lean Manufacturing, Six Sigma, and continuous improvement methodologies to improve manufacturing performance.
• Partners with Design Engineering to support Design for Manufacturing (DFM) initiatives and improve product manufacturability.
• Analyzes production metrics and key performance indicators (KPIs) to prioritize improvement initiatives and monitor results.
• Supports qualification and validation of manufacturing processes, tooling, materials, and equipment.
• Assists with production readiness reviews, capacity planning, and production ramp-up activities.
• Ensures compliance with aerospace quality standards, customer requirements, and regulatory requirements.
• Provides technical guidance and hands-on support to production personnel and cross-functional manufacturing teams.

KNOWLEDGE

• Composite aerospace manufacturing processes, including hand layup, automated layup, vacuum bagging, autoclave processing, out-of-autoclave curing, bonding, machining, and assembly.
• Lean Manufacturing, Six Sigma, continuous improvement methodologies, and statistical process control.
• Root cause analysis and corrective action processes.
• Aerospace manufacturing standards and quality systems, including AS9100.
• Composite inspection methods, NDI/NDT techniques, and quality assurance practices.
• Manufacturing documentation, process development, and production controls.
• ERP/MRP systems and Manufacturing Execution Systems (MES) preferred.

COMPETENCIES

• Strong analytical and problem-solving abilities.
• Ability to identify manufacturing inefficiencies and implement practical solutions.
• Effective project management and organizational skills.
• Strong verbal and written communication skills.
• Ability to collaborate effectively with cross-functional teams.
• Ability to manage multiple priorities in a fast-paced manufacturing environment.
• Strong attention to detail and commitment to quality.
• Ability to work independently while supporting team objectives.

EXPERIENCE AND EDUCATION

• High school diploma or equivalent required
• Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Aerospace Engineering, Materials Engineering, or a related technical discipline required.
• Minimum of seven (7) years of manufacturing engineering experience, preferably supporting aerospace composite manufacturing.
• Demonstrated experience with composite fabrication, assembly, and manufacturing process optimization.
• Experience leading continuous improvement, root cause analysis, and process validation activities.
• Lean Manufacturing and/or Six Sigma certification preferred.
• Experience supporting aerospace OEMs, Tier 1 suppliers, or advanced composite manufacturing organizations preferred.

WORKING CONDITIONS

• Work is performed in both office and manufacturing environments.
• Frequent interaction with production equipment, tooling, and manufacturing personnel.
• Requires prolonged standing and walking on the production floor.
• May occasionally lift and move materials weighing up to 25 pounds.
• Personal protective equipment (PPE) is required in designated production areas.
• Occasional travel may be required.
• May require extended work hours to support production schedules and operational priorities.

WORK AUTHORIZATION/SECURITY CLEARANCE

• U.S. Citizen or Permanent Resident
• If a Security Clearance is required:
  • Candidates "must/may need" to be able to obtain and maintain a DoD Security Clearance
  • Successful candidates must be able to secure Program Access approval

Duties, responsibilities, and activities may change, or new ones may be assigned at any time with or without notice.