Senior Manufacturing Engineer – Electronics Manufacturing

Senior Manufacturing Engineer – Electronics Manufacturing

Location: Frederick, MD
Work Arrangement: Onsite, with occasional work at the Greenbelt, MD facility

We are seeking a hands-on Senior Manufacturing Engineer with experience in electronics manufacturing, electromechanical systems, circuit card assembly (CCA) troubleshooting, and corrective action implementation. This role serves as a technical lead between Engineering, Manufacturing Operations, Quality, and contract manufacturers, driving resolution of production failures and implementing robust corrective actions.

Overview

The engineer will lead investigations into production test failures, electromechanical issues, CCA defects, supplier quality concerns, and field returns. Success in this role requires strong electrical troubleshooting skills, deep manufacturing process knowledge, structured root cause analysis capabilities, and the ability to drive containment, corrective action, and verification through completion.

The ideal candidate is comfortable working independently, making evidence-based decisions, and translating technical findings into practical manufacturing improvements.

Responsibilities

• Troubleshoot and resolve technical issues during production and testing; apply structured critical thinking and collaborate cross-functionally to drive effective solutions.
• Review and analyze electrical schematics, wiring diagrams, and circuit documentation to support troubleshooting, test coverage improvements, and sustainment activities.
• Diagnose CCA failures using component-level analysis, signal tracing, and power/ground integrity checks.
• Investigate manufacturing and quality issues with internal teams and contract manufacturers; implement corrective actions to prevent recurrence.
• Perform failure analysis on warranty returns and in-process test failures and identify systemic root causes.
• Manage product sustainment throughout the full lifecycle, including updates, obsolescence, and end-of-life planning.
• Improve product reliability, manufacturability, and performance through data-driven analysis, electrical troubleshooting, and targeted design or process modifications.
• Create and maintain technical documentation, including drawings, schematics, test procedures, and BOMs.
• Manage controlled changes through formal engineering change processes.
• Identify and implement product or process improvements to enhance quality, efficiency, and cost-effectiveness.
• Lead corrective and preventive action (CAPA) activities, including ECO/ECP initiation, documentation updates, and controlled release.
• Conduct structured root cause analyses using 8D, 5-Whys, and Ishikawa methodologies.
• Manage containment, deviations, and rework paths; collaborate with suppliers on SCARs and quality improvement plans.
• Maintain Control Plans, FMEAs, and Inspection Plans and ensure traceability from issue discovery through resolution.
• Set up, calibrate, and maintain production test equipment and fixtures.
• Ensure adequate test coverage with engineering and contract manufacturing partners and perform Gage R&R studies.
• Support bench-level electrical debugging, signal probing, and controlled experiments to validate failure modes and corrective actions.

Required Qualifications

• U.S. Citizenship required, with ability to obtain a Secret clearance.
• Bachelor’s degree in Electrical, Mechanical, Systems, Mechatronics, or a related engineering field.
• 5–10 years of experience in manufacturing engineering, sustaining engineering, electronics production, electromechanical systems, or hardware failure analysis.
• Demonstrated experience leading root cause investigations and implementing corrective actions for manufacturing defects, test failures, supplier issues, or field returns.
• Experience collaborating with manufacturing technicians, suppliers, Quality, and cross-functional engineering teams.
• Strong communication, documentation, and organizational skills.
• Ability to work onsite in Frederick, MD, with occasional work at the Greenbelt, MD facility.

Desired Qualifications

• Hands-on experience troubleshooting CCAs, electronic hardware, and electromechanical systems.
• Strong understanding of electrical schematics, wiring diagrams, component-level diagnostics, and electrical test methods.
• Experience using oscilloscopes, multimeters, power supplies, and other diagnostic equipment.
• Background in defense, aerospace, military electronics, instrumentation, navigation, or other high-reliability hardware environments.
• Experience with contract manufacturing operations, including assembly, integration, production testing, and supplier quality.
• Familiarity with IPC standards, ESD controls, soldering/rework, and electronics manufacturing quality requirements.
• Experience with 8D, CAPA, SCARs, FMEA, control plans, nonconformance management, and continuous improvement methodologies.
• Experience with engineering change management, BOM control, component obsolescence, and alternate part qualification.
• Familiarity with MES systems, test data analysis, and quality management systems.