Senior Manufacturing Engineer - Operations Support

The Senior Manufacturing Engineer is a key member of the Operations Team, responsible for developing, optimizing, and supporting manufacturing processes to ensure operational excellence. This role plays a critical part in establishing efficient production setups, implementing best practices, and enabling daily operations to achieve quality, safety, and productivity goals.

Essential Duties and Responsibilities:

Develop and optimize production and assembly processes for subassembly and full tool integration, including repeatability and sustainability

Create an assessment of the capability and level on the shop floor, split per different department/team and competence, to follow-up with a personalized training plan

Lead first-article builds and support new product introductions (NPI) from prototype to
production

Collaborate with the engineering department and customers to ensure manufacturability and Copy Exact compliance

Create and maintain work instructions, OMS, and process documentation

Troubleshoot build issues and drive root cause analysis and corrective actions

Interface with quality assurance to ensure compliance with ISO 9001.

Provide technical support to production teams and train technicians in new processes

Prior leadership of engineering teams in a manufacturing environment.

Lead and manage the Process and Manufacturing Engineering teams supporting operations.

Own the development, documentation, and continuous improvement of manufacturing processes for complex aerospace components.

Serve as the technical authority for machining process design, routing development, work instructions, tooling strategies, and capacity planning.

Drive process capabilities, and defect reduction using APQP, PFMEA, control plans, and SPC where appropriate in support of new product introductions (NPI) from prototype to production.

Partner with Quality, Operations, and Program Management to ensure on-time, compliant delivery to prime customers.

Ensure full compliance with government contract requirements, including:

Lead cost reduction, cycle time reduction, and yield improvement initiatives in a low-volume, high-mix environment.

Support quoting and estimating with manufacturing input, process plans, and cost models.

Provide hands-on technical mentorship to engineers, supervisors, and machinists.

Champion standard work, visual management, and lean manufacturing practices without compromising quality or compliance.

Lead root cause analysis and corrective action for process escapes and systemic issues.

Education and Experience:

Bachelor’s degree in Mechanical, Electrical, or Manufacturing Engineering; or equivalent experience

10+ years of progressive experience in manufacturing or process engineering.

5+ years of direct machine shop, metal fabrication experience in precision machining (CNC milling, turning, multi-axis machining, MIG/TIG, Laser cutting and press brake).

Lean Six Sigma Black Belt or equivalent continuous improvement certification.

Hands-on experience with high-mix, low-volume builds and pilot production

Experience in cleanroom protocols a plus.

Proficiency in CAD tools, ERP systems, and data analysis software (e.g., Excel, Python)

Excellent problem-solving, communication, and project management skills

(Physical) Requirements:

Exhibit good interpersonal skills to communicate change, train shop employees and work with management.

Ability to move around the facility and visit production areas, which may include walking and standing for the majority of the time.

Hybrid work between GEMBA and office. Candidate must be able navigate both work environments effectively.

Must be able to remain focused and prioritize tasks to satisfy project requirements.

Prolonged periods sitting at a desk and working on a computer.

Must be able to occasionally lift 35 pounds.

Must be able to concentrate and remain focused in an open office environment with potential distractions.

Occasional travel may be required for training or coordination with other VDL locations.