Sr Manufacturing Engineer

Sr Manufacturing Engineer

Dallas, TX

The Sr Manufacturing Engineer supports the development, deployment, and scaling of advanced manufacturing systems across Deterrence Defense production facilities. This role owns critical manufacturing processes, driving equipment strategy, leading commissioning activities, and ensuring systems operate safely, efficiently, and reliably. The engineer will collaborate with cross-functional engineering and operations teams to solve complex electromechanical and process challenges in fast-paced, high-throughput production environments.

Key Responsibilities

• Lead design, development, installation, and ramp-up of advanced manufacturing equipment and automated systems.
• Own performance, reliability, and safety of assigned production equipment.
• Conduct root-cause analysis across mechanical, electrical, controls, and process domains.
• Improve equipment and process performance through data-driven experimentation and continuous improvement.
• Develop specifications, work instructions, operating procedures, and maintenance documentation.
• Work with internal stakeholders and suppliers to define requirements, conduct design reviews, and validate equipment.
• Support process controls, PLC/HMI interactions, automation troubleshooting, and system bring-up.
• Ensure equipment meets all ergonomic, safety, and regulatory standards.
• Identify critical spare parts and support preventive and predictive maintenance planning.

Qualifications

• Bachelor's degree in Mechanical, Electrical, Chemical, or related engineering field.
• Extensive experience in high-volume or high-precision manufacturing environments.
• Strong understanding of core engineering principles applied to production systems.
• Demonstrated ability to troubleshoot complex electromechanical equipment.
• Ability to travel between facilities and supplier locations as required.

Preferred Skills

• Experience with cycle time modeling, bottleneck identification, and throughput optimization.
• Proficiency with DOE, SPC, Cp/Cpk analysis, Gage R&R, and real-time data monitoring.
• Understanding of OEE tracking, yield analysis, and defect reduction methods.
• Familiarity with PLCs, HMIs, SCADA, safety circuits, and automation debugging.
• Knowledge of servo systems, pneumatics, vacuum systems, and motion tuning.
• Experience leading FAT/SAT, commissioning, validation, and equipment acceptance.
• Background in predictive maintenance, reliability engineering, and structured downtime analysis.
• Proficiency in line balancing, takt time planning, ergonomic workstation design, and process documentation.
• Experience with PFMEA, control plans, PFDs, and end-to-end process mapping.
• Supplier qualification experience including audits and vendor management.
• Strong RCA skills using 8D, A3, DMAIC, Ishikawa, and Five Whys methodologies.
• Knowledge of forging, CNC machining, heat treatment, welding, and mechanical assembly processes.