Lead Manufacturing Engineer

Worker Type Regular Job Description The Lead Manufacturing Engineer is responsible for defining, launching, and improving manufacturing processes for Titan C-UAS electrical and mechanical products, with a strong focus on contract manufacturing (CM). This role supports the technical transfer of products to CMs, ensures robust production readiness, and drives ongoing process improvements using data and structured problem-solving. The Lead Manufacturing Engineer collaborates closely with design engineering, supply chain, quality, and CM partners to achieve reliable, cost effective, and scalable production. Key Responsibilities Include: Contract Manufacturing Technical Support - Serve as a primary day to day technical contact for contract manufacturers producing electrical and mechanical assemblies. Support NPI and production transfers to CMs by defining build strategy, documenting processes, and resolving technical issues during initial builds and ramp. Review and provide feedback on CM work instructions, assembly procedures, inspection plans, and test procedures to ensure they meet product and quality requirements. Monitor CM performance (yield, rework, scrap, cycle time) and support improvement actions in partnership with Supply Chain and Quality. Participate in CM audits, build readiness reviews, and on site troubleshooting as required. Process Development & Setup (Electrical & Mechanical) - Develop, maintain, and improve manufacturing processes for electrical and mechanical assemblies including PCB-based products, harnesses, machined and sheet metal parts, and system-level integrations. Establish and maintain standard times and sequences of operations for current and future production processes, both internal and at CMs. Generate and update work instructions, assembly procedures, visual aids, and other documentation to control and standardize manufacturing processes. Participate in the design and development of manufacturing workflows and equipment layout for efficient, safe, and ergonomic operations. Support Design for Manufacturability/Assembly (DFM/DFA) activities with design engineering and CMs to improve build robustness, yield, and cost. Data-Driven Continuous Improvement - Analyze production metrics (yield, capacity, cost, process capability) from internal builds and CMs to identify trends and improvement opportunities. Help implement Lean Manufacturing and Six Sigma tools to drive reductions in cost, lead time, and variability. Participate in PFMEA and support DFMEA to identify and mitigate manufacturing risks and ensure adequate process controls. Support development of manufacturing strategies and capacity models for new and existing products, including inputs for capital and tooling needs. Tooling, Fixtures, and Make/Buy Support - Support cost estimating and requirements definition for new tooling, fixtures, and test equipment needed to support manufacturing at CMs and internal facilities. Contribute to Make/Buy analysis and trade studies in collaboration with cross functional teams for key assemblies and processes. Provide guidance on process capabilities and equipment utilization to best align design intent and manufacturing methods. Production Floor & Hands-On Support - Provide hands-on support to internal production and CM builds, including troubleshooting integration and assembly issues. Participate in root cause analysis and corrective action activities for issues related to materials, design, tooling, process, or operator error. Basic Qualifications (Required Skills & Experience): Bachelor’s degree in Industrial, Mechanical, Manufacturing, Electrical Engineering, or related field; or equivalent combination of education, training, and experience. 5–10+ years of experience in Manufacturing, Industrial, Mechanical, Electrical, or Test Engineering in aerospace, defense, automotive, or similar high reliability industries. Experience supporting or managing contract manufacturers or external suppliers for electrical and/or mechanical assemblies. Working knowledge of electro mechanical manufacturing, including interpretation of drawings, specifications, and Bills of Material. Familiarity with PCB-based products, sheet metal, machined parts, and basic integration/assembly processes. Experience with Lean Manufacturing and Six Sigma principles and tools for process development and control. Proficient in Microsoft Office (Word, Excel, PowerPoint, Outlook; Visio/Project a plus). Familiarity with statistical analysis tools (e.g., MiniTab), MRP/ERP systems (Oracle preferred), PLM/Change systems (e.g., Agile), and CAD programs (SolidWorks preferred). Experience working with ECO/ECN processes. Ability and willingness to travel to CM/supplier sites (up to ~25%, as needed). Other Qualifications & Desired Competencies: Certification in Lean / Six Sigma (Green Belt or higher) preferred. Demonstrated problem-solving and analytical skills, including root cause analysis techniques (5 Why, fishbone, 8D participation). Strong organization, planning, and time management skills; able to handle multiple priorities across internal and CM activities. Effective verbal and written communication skills; able to collaborate with engineering, operations, supply chain, quality, and CM personnel. Ability to work within defined requirements and deadlines and to perform independently with moderate oversight. Comfortable in a fast paced, deadline driven environment where small teams share a broad variety of duties. Demonstrated initiative, ownership, and a continuous improvement mindset. Experience working within ISO based or similar quality systems. Physical Demands: Ability to work in an office environment (constant). Ability to sit and stand for extended periods; talk, hear, and use hands and fingers to operate a computer and telephone keyboard (frequent). Ability to work in lab and production environments, including CM facilities, as needed (occasional). Special Requirements: U.S. Citizenship required. Occasional domestic and international travel may be required. Clearance Level No Clearance The salary range for this role is: $122,500 - $187,000 AeroVironment considers several factors when extending an offer, including but not limited to, the location, the role and associated responsibilities, a candidate’s work experience, education/training, and key skills. ITAR Requirement: This position requires access to information that is subject to compliance with the International Traffic Arms Regulations (“ITAR”) and/or the Export Administration Regulations (“EAR”). In order to comply with the requirements of the ITAR and/or the EAR, applicants must qualify as a U.S. person under the ITAR and the EAR, or a person to be approved for an export license by the governing agency whose technology comes under its jurisdiction. Please understand that any job offer that requires approval of an export license will be conditional on AeroVironment’s determination that it will be able to obtain an export license in a time frame consistent with AeroVironment’s business requirements. A “U.S. person” according to the ITAR definition is a U.S. citizen, U.S. lawful permanent resident (green card holder), or protected individual such as a refugee or asylee. See 22 CFR § 120.15. Some positions will require current U.S. Citizenship due to contract requirements. Benefits: AV offers an excellent benefits package including medical, dental vision, 401K with company matching, a 9/80 work schedule and a paid holiday shutdown. For more information about our company benefit offerings please visit: We also encourage you to review our company website at to learn more about us. Principals only need apply. NO agencies please. About AV: AV isn’t for everyone. We hire the curious, the relentless, the mission-obsessed. The best of the best. We don’t just build defense technology—we redefine what’s possible. As the premier autonomous systems company in the U.S., AV delivers breakthrough capabilities across air, land, sea, space, and cyber. From AI-powered drones and loitering munitions to integrated autonomy and space resilience, our technologies shape the future of warfare and protect those who serve. Founded by legendary innovator Dr. Paul MacCready, AV has spent over 50 years pushing the boundaries of what unmanned systems can do. Our heritage includes seven platforms in the Smithsonian—but we’re not building history, we’re building what’s next. If you're ready to build technology that matters—with speed, scale, and purpose—there’s no better place to do it than AV. We are proud to be an EEO/AA Equal Opportunity Employer, including disability/veterans. AeroVironment, Inc. is an Equal Employment Opportunity (EEO) employer and welcomes all qualified applicants. Qualified applicants will receive fair and impartial consideration without regard to race, sex, color, religion, national origin, age, disability, protected veteran status, genetic data, sexual orientation, gender identity or other legally protected status. ITAR U.S. Citizenship required About AV: AV isn’t for everyone. We hire the curious, the relentless, the mission-obsessed. The best of the best. We don’t just build defense technology—we redefine what’s possible. As the premier autonomous systems company in the U.S., AV delivers breakthrough capabilities across air, land, sea, space, and cyber. From AI-powered drones and loitering munitions to integrated autonomy and space resilience, our technologies shape the future of warfare and protect those who serve. Founded by legendary innovator Dr. Paul MacCready, AV has spent over 50 years pushing the boundaries of what unmanned systems can do. Our heritage includes seven platforms in the Smithsonian—but we’re not building history, we’re building what’s next. If you're ready to build technology that matters—with speed, scale, and purpose—there’s no better place to do it than AV. Careers at AeroVironment