Directed Energy Senior Manufacturing and Process Engineer

Worker Type Regular Job Description Summary The Directed Energy Senior Manufacturing and Process Engineer is responsible for developing, implementing, optimizing, and sustaining manufacturing processes for complex products and assemblies. This role serves as a technical manufacturing engineering organization, working cross-functionally with Design Engineering, Quality, Supply Chain, Operations, and Test Engineering to improve productivity, quality, cost, safety, and delivery performance. The Senior Manufacturing and Process Engineer will lead process-development and continuous-improvement projects, support Research & Development, New Product Development and Introduction, resolve difficult production issues, and provide technical mentorship to less experienced engineers and manufacturing personnel.

• Develop, document, validate, and improve manufacturing processes for complex products, assemblies, and test systems.
• Support manufacturing and process engineering activities for new product introduction, design transfers, and production transitions.
• Review product designs for manufacturability, assembly, inspection, serviceability, and cost effectiveness.
• Create and maintain manufacturing documentation, including:
  Work instructions Manufacturing process specifications Standard operating procedures Process flow diagrams Assembly aids and tooling requirements Bills of material and routing information.
• Design and implement process improvements using Lean Manufacturing, Six Sigma, root-cause analysis, and other continuous-improvement methodologies.
• Support investigations into production problems, nonconformances, yield losses, and process escapes.
• Help develop corrective and preventive actions and verify their effectiveness.
• Establish process parameters, acceptance criteria, inspection methods, and production controls.
• Design or coordinate the development of fixtures, tooling, gauges, test equipment, and other production aids.
• Support equipment selection, installation, qualification, and maintenance planning.
• Analyze production data to identify trends, constraints, waste, and opportunities for improvement.
• Support process validation activities, including capability studies, first article inspections, qualification testing, and production readiness reviews.
• Partner with Quality Engineering to support root-cause analysis, material review board activities, and corrective-action investigations.
• Support supplier development, component qualification, and outsourced manufacturing processes as needed.
• Provide technical guidance and mentorship to Manufacturing/Process Engineers I and II and production personnel.
• Participate in design reviews, production readiness reviews, risk assessments, and program reviews.
• Ensure processes comply with applicable engineering, quality, safety, environmental, and regulatory requirements.
• Support production operations and troubleshoot urgent manufacturing issues.
• Perform other duties as assigned.

• Bachelor’s degree in Manufacturing Engineering, Mechanical Engineering, Industrial Engineering, Electrical Engineering, or a related technical field.
• Typically, 5-8 years of relevant manufacturing or process engineering experience, or an equivalent combination of education and experience.
• Demonstrated experience developing and sustaining manufacturing processes for complex products or assemblies.
• Experience with new product introduction, production transition, and design-for-manufacturability activities.
• Proven ability to support cross-functional technical projects.
• Strong knowledge of root-cause analysis, corrective action, process capability, and continuous-improvement methods.
• Experience creating and maintaining…