Senior Process Engineer (Denver Metropolitan Area)

Company Overview

ExoTerra is a world leader in solar electric propulsion systems and space exploration satellites. The company develops Hall Thrusters, propulsion modules, microsatellites and launch vehicle upper stages. We have been awarded multiple propulsion module and satellite contracts.

Position Summary

We are seeking a highly skilled and results-driven Process Engineer to lead the development, industrialization, and ramp-up of manufacturing processes for a new high-rate aerospace production facility. This role is critical in establishing robust, scalable, and efficient processes that meet stringent aerospace quality, cost, and delivery requirements.

The ideal candidate will have deep experience in manufacturing process design, production ramp, and aerospace/precision manufacturing environments, with a strong focus on throughput optimization, quality assurance, and lean principles.

Essential Functions:

Facility & Process Setup

• Lead the design, development, and implementation of manufacturing processes for a new aerospace production site.
• Define and document end-to-end production workflows, including material flow, tooling, equipment, and staffing models.
• Support facility layout planning to optimize throughput, ergonomics, and safety.
• Collaborate with cross-functional teams to ensure readiness for production ramp.

Process Development & Industrialization

• Develop and validate manufacturing processes, work instructions, and standard operating procedures (SOPs).
• Design and implement process controls to ensure repeatability, quality, and compliance with aerospace standards (e.g., AS9100).
• Select and qualify equipment, tooling, and automation solutions.
• Conduct process capability studies (Cp, Cpk) and establish control plans.

Production Ramp & High-Rate Manufacturing

• Lead production ramp-up efforts, achieving target rate, yield, and cost metrics.
• Identify and eliminate bottlenecks to ensure high-rate production throughput.
• Implement lean manufacturing techniques (e.g., takt time, line balancing, value stream mapping).
• Drive continuous improvement initiatives to enhance productivity and reduce waste.

Quality & Compliance

• Ensure processes meet aerospace regulatory and quality requirements.
• Support First Article Inspection (FAI) and qualification builds.
• Partner with Quality teams to resolve non-conformances and root cause investigations.
• Implement error-proofing (poka-yoke) and robust quality controls.

Data, Metrics, and Continuous Improvement

• Develop and track key performance indicators (KPIs), such as yield, cycle time, and OEE.
• Utilize data analytics to identify improvement opportunities.
• Lead Six Sigma / root cause analysis initiatives to improve process stability.

Cross-Functional Collaboration

• Work closely with Design Engineering, Supply Chain, Quality, Operations, and Facilities teams.
• Support supplier development and integration of external manufacturing partners.
• Provide technical leadership during design reviews and production readiness assessments.

Basic Qualifications

• Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, or related field.
• 5–10+ years of experience in manufacturing/process engineering, preferably in aerospace or regulated industries.
• Proven experience in launching new production lines or facilities.
• Strong knowledge of high-rate production environments and process scaling.
• Experience with lean manufacturing, Six Sigma, or continuous improvement methodologies.
• Familiarity with aerospace quality systems (AS9100, NADCAP).
• Experience with process validation, PFMEA, control plans, and statistical process control (SPC).

Preferred Qualifications

• Excellent verbal and written communication skills
• Experience with Spacecraft Fabrication and Test
• Experience with non-conformance resolution
• Experience with manufacturing process development
• Experience with Programming

Export Control / Compliance Requirements

To conform to U.S. Government space technology export regulations, including the International Traffic in Arms Regulations (ITAR) you must be a U.S. citizen, lawful permanent resident of the U.S., protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain the required authorizations from the U.S. Department of State.

Compensation & Benefits

The good faith base salary range (OR hourly range) for this role is $110,000-$135,000 at the time of this posting. Where you fall within the ,range depends on your experience, skills, and location. This range reflects base salary only and does not include benefits or bonus/incentive. This range may be adjusted in the future.

ExoTerra offers a comprehensive, total compensation package, which includes competitive salary, a discretionary annual bonus plan, paid time off (PTO), a comprehensive health benefit package and various other benefits. When you join our team, you’re not just an employee; you become part of a dynamic community dedicated to innovation and excellence.

Equal Employment Opportunity Statement

ExoTerra is an Equal Opportunity Employer. Employment decisions are made without regard to race, color, religion, national or ethnic origin, sex, sexual orientation, gender identity or expression, age, disability, protected veteran status or other characteristics protected by law.