Senior Electronics Manufacturing Engineer

Job Description

Job Description

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