Senior Electronics Manufacturing Engineer

Senior Electronics Manufacturing Engineer to drive electronics manufacturing, design for manufacturability (DFM/DFMA), production readiness, and scalable factory design across multiple sUAS platforms. This role partners with Design Engineering, Quality, Supply Chain, and Operations to lead DFM/DFMA, Design for Test (DFT), New Product Introduction (NPI) industrialization, tooling and fixturing, built-in quality, capacity planning, manufacturing automation, and factory/line layout optimization for high-volume manufacturing. The role will improve throughput, cost, quality, safety, and production scalability across complex electrical and electromechanical systems.

Responsibilities – What You’ll Do

• Collaborate with Design Engineering to provide DFM/DFMA and DFT input from concept through production release; deliver clear, prioritized recommendations to improve electrical designs for manufacturability, assembly, testability, reliability, and cost in high-volume production.
• Lead optimization of electrical manufacturing, assembly, and test processes for new and existing products, including avionics, power distribution, RF components, embedded systems, PCBAs, motors, controllers, and cable harnesses.
• Develop, validate, release, and continuously improve manufacturing documentation, including work instructions, process flows, routings, control plans, and test procedures.
• Troubleshoot production and test issues across assemblies and systems; perform root cause analysis (RCA) and implement corrective and preventive actions (CAPA) to improve safety, quality, delivery, first-pass yield, and cost.
• Support the development, validation, and sustainment of electrical test systems, production test equipment, and test fixtures to meet performance, uptime, and Overall Equipment Effectiveness (OEE) requirements.
• Collaborate with Quality, Supply Chain, and suppliers to support product qualification, component availability, supplier readiness, and inspection/test strategies, including PFMEA, control plans, and in-process quality controls.
• Identify, evaluate, and industrialize manufacturing automation opportunities for high-volume assembly and test; support equipment specification, factory layout, commissioning, validation, and production ramp-up of semi-automated and fully automated workcells and production lines.
• Define and validate manufacturing tooling, fixturing, and gaging, including assembly jigs, test fixtures, torque tools, and poka-yoke/error-proofing devices, to enable safe, repeatable, and efficient production.
• Partner with NPI teams to plan and execute prototype, pilot, ramp, and production builds, including line readiness, tooling, operator training, manufacturing documentation, and build-learning capture.
• Drive continuous improvement initiatives using Lean Manufacturing methodologies such as 5S, Kaizen, Kanban, SMED, and line balancing to reduce waste, improve throughput, increase first-pass yield (FPY), and strengthen built-in quality.
• Support manufacturing cost and capital investment decisions by quantifying labor, equipment, takt/cycle time, capacity, and space requirements; contribute to make/buy analysis, equipment selection, and capital justification.

Qualifications – Requirements

• B.S. in Electrical Engineering or a related engineering discipline with 8 years of experience directly supporting NPI, industrialization, and sustaining electrical manufacturing; experience in aerospace/defense manufacturing and high-mix electromechanical assembly preferred.
• Demonstrated success leading cross-functional DFM/DFMA, DFT, and PFMEA efforts from product design through manufacturing release.
• Strong NPI/industrialization experience across prototype, pilot, ramp, and sustainment phases, including production line readiness, manufacturing documentation, ramp-to-rate, and continuous improvement.
• Experience supporting high-volume, high-throughput manufacturing, including designing, deploying, and scaling automated or semi-automated assembly and test lines.
• Demonstrated experience developing automation equipment requirements, specifications, and acceptance criteria/URS; supporting capital justification; and participating in Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), process validation, and production ramp-to-rate.
• Working familiarity with industrial automation technologies and manufacturing performance metrics, including robotics/cobots, machine vision, automated torque/dispense systems, conveyors, PLC/HMI concepts, OEE, and downtime analysis.
• Hands-on experience defining requirements for manufacturing tooling, fixtures, and gages; coordinating design and fabrication; conducting acceptance testing; and releasing equipment into production.
• Working knowledge of built-in quality, quality at the source, poka-yoke, control plans, PFMEA, gage R&R, in-process inspection, and manufacturing process controls; demonstrated ability to partner with Quality to improve process capability and reduce quality escapes.
• Proven capability in capacity planning, line balancing, labor standards, cycle-time optimization, and time studies; advanced Microsoft Excel and data analysis skills required. Experience with Minitab, LabVIEW, and Microsoft Power BI is a plus.
• Proficiency with manufacturing layout and visualization tools, including Visio and AutoCAD, along with electrical CAD tools such as Altium Designer and generating Engineering Change Orders (ECOs) using Product Lifecycle Management (PLM) systems such as Duro while applying ergonomic and safety principles.
• Familiarity with ERP/MES master data and manufacturing documentation, including BOMs, routings, work centers, and revision control; Lean Manufacturing/Six Sigma experience and strong cross-functional communication skills.
• Must be eligible to obtain and maintain a U.S. Secret security clearance or higher, as required.

Senior Electronics Manufacturing Engineer, electronics manufacturing, Electrical Engineering, DFM/DFMA, Design for Test (DFT), New Product Introduction (NPI), NPI/industrialization, high-volume manufacturing, high-volume production, high-volume, high-throughput manufacturing, sUAS platforms, aerospace/defense manufacturing, avionics, RF components, embedded systems, PCBAs, cable harnesses, manufacturing documentation, control plans, root cause analysis (RCA), corrective and preventive actions (CAPA), electrical test systems, Overall Equipment Effectiveness (OEE), PFMEA, manufacturing automation, manufacturing tooling, poka-yoke/error-proofing, line readiness, continuous improvement, Lean Manufacturing, 5S, Kaizen, Kanban, SMED, line balancing, first-pass yield (FPY), make/buy analysis, capital justification, automation equipment requirements, Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), process validation, industrial automation, machine vision, PLC/HMI, built-in quality, gage R&R, capacity planning, time studies, Microsoft Excel, Microsoft Power BI, Visio, AutoCAD, Altium Designer, Engineering Change Orders (ECOs), Product Lifecycle Management (PLM), ERP/MES, BOMs, Lean Manufacturing/Six Sigma, U.S. Secret security clearance