Senior Manufacturing Engineer

As a Manufacturing Engineer focused on NPI and production readiness, you will be the architect of the production ecosystem. You will bridge the gap between initial hardware design and full-rate production by designing, simulating, and implementing world-class manufacturing systems. Your mission is to ensure that every subcomponent has a defined, validated path to flight/delivery, minimizing waste and maximizing OEE (Overall Equipment Effectiveness) through rigorous Value Stream Mapping, DFM collaboration, and data-driven line balancing.

Key Responsibilities

• Manufacturing Systems Design & Simulation
  • Value Stream Mapping (VSM): Define the end-to-end process flow for hardware, accounting for technical validation, cycle times, resource allocation, and equipment requirements.
  • Factory Layout & Flow: Design production layouts that prioritize hardware flow and minimize wasted movement, ensuring all facility needs, safety standards, and industry requirements are documented and met.
  • Modeling & Simulation: Input production line data into simulators to visualize flow, identify potential bottlenecks, and mitigate risks to the manufacturing system before physical implementation.
  • Signaling & Logistics: Perform the mathematical calculations to balance production lines; design and implement IPKs, RIPs, KANBAN systems, and visual signaling strategies.
• Design for Manufacturability (DFM) & Collaboration
  • Design Integration: Collaborate with Design, Quality, and Systems teams to ensure manufacturability is "baked into" the hardware at the earliest stages.
  • Requirement Advocacy: Negotiate between design intent and manufacturing capability to ensure all hardware requirements are clearly stated on drawings and feasible for the production line.
  • Risk Mitigation: Identify specific design-based risks to the manufacturing system and prioritize mitigation strategies during the production readiness phase.
• Production Readiness & "Burst Build" Execution
  • Resource Planning: Define immediate needs for personnel, custom tooling, and equipment per workstation to feed into hiring plans and facilities updates.
  • Mixed Model Strategy: Incorporate manufacturing actions into mixed-model calculations to define the resources needed for varied product throughput.
  • Workstation Architecture: Transition "Burst Build" learnings into permanent workstation designs, including shadow boards, specialized lighting, validation methods, and ergonomic considerations.
  • Documentation: Author and refine high-fidelity Work Instructions (WIs) based on iterative learnings from development builds.
• Continuous Improvement & Off-Nominal Planning
  • Rework & Off-Line Strategy: Define "off-nominal" plans to accommodate hardware rework without downing the main production line.
  • Bottleneck Optimization: Continuously track production bottlenecks and consistent rework areas to enforce process improvements and validation testing.
  • Change Management: Establish and prioritize methods to document, track, and enforce system changes based on risk priority, ensuring visibility across the organization.

Qualifications

• B.S. in Mechanical, Aerospace, or Industrial Engineering (or equivalent experience).
• 4+ years of applicable manufacturing engineering experience.
• Proven track record in NPI (New Product Introduction) within high-complexity industries (e.g., Aerospace, Automotive, Medical Devices).
• Proficiency in CAD (for layout design) and production simulation software.
• Deep understanding of Lean Manufacturing, Six Sigma, and KANBAN signaling.
• Experience with Value Stream Mapping and Mixed Model line balancing.
• Exceptional negotiation skills to bridge the gap between design engineering and production technicians.

Colorado law requires us to tell you the base compensation range of this role, which is $110,000 - $130,000, determined by your education, experience, knowledge, skills, and abilities. What we can’t quantify for you are the exciting challenges, supportive team, and amazing culture we enjoy.

Classification: Full-time, Exempt