Sr Manufacturing Process Engineer; UAV​/USV

Ideal Aerosmith is a leading supplier of precision inertial guidance test systems, flight motion simulators, innovative defense solutions in support of the warfighter, and a premier provider of aerospace test engineering services, ATE system engineering, and quality contract manufacturing services to the aerospace industry. We're experts and we earn that title every day with our customers through innovative engineering, manufacturing, and sustainment of world-class motion and electric test solutions and services.

Here, we don’t just solve complex problems - we redefine what’s possible. Every role at Ideal Aerosmith supports a lean culture through continuous improvement - ongoing, incremental enhancements to products, processes, or services aimed at reducing waste and boosting efficiency, customer service, and performance. With a team of skilled problem solvers and a culture that thrives on tackling challenges head-on, we are dedicated to our clients' success.

Enjoy competitive benefits, a supportive work environment, and every other Friday off to recharge.

We are seeking a Senior Manufacturing Process Engineer to lead the development, optimization, and scaling of system-level integration and production processes supporting our Unmanned Aerial Vehicle (UAV) and Unmanned Surface Vehicle (USV) programs. This role partners closely with Engineering, Quality, Supply Chain, and Program Management to ensure manufacturing execution is disciplined, repeatable, scalable, and production-ready.

The ideal candidate will have a strong background in aerospace or complex electromechanical manufacturing environments, including system integration, production flow design, rate-readiness planning, and manufacturing documentation control. This position plays a critical role in transitioning advanced platforms from prototype builds to rate-capable production. The Senior Manufacturing Process Engineer will establish standardized work instructions, MBOM structures, integration sequencing strategies, and production control frameworks designed to sustain long-term program growth within configuration-controlled environments.

• Lead manufacturing system development for new UAV production facility stand-up, including integration cell design, documentation frameworks, and process governance structures
• Design and implement scalable system‑level integration processes
• Develop standardized production frameworks across programs and product lines
• Establish manufacturing flow, line layout, and integration sequencing strategies
• Define tooling, fixtures, and process control requirements
• Lead MBOM development and manufacturing structure definition
• Define production infrastructure requirements including tooling strategy, workspace layout, integration cell architecture, and material flow systems

• Lead transition from prototype builds to low‑rate and full‑rate production
• Conduct production readiness reviews and rate capability assessments
• Identify systemic bottlenecks and implement structural improvements
• Develop capacity planning inputs in coordination with Production Leadership
• Drive measurable improvements in yield, throughput, and repeatability
• Define and implement integration process controls and verification checkpoints to ensure end‑item quality, configuration integrity, and first‑pass yield performance at production rate
• Establish production‑to‑test handoff criteria and ensure manufacturing processes support ground test, acceptance testing, and flight readiness requirements
• Establish standardized manufacturing change control processes aligned with engineering configuration management
• Define and monitor key manufacturing performance metrics including first‑pass yield, integration defect rate, rework hours, and rate capability

• Serve as escalation point for complex integration and assembly issues
• Lead root cause and corrective action (RCCA) efforts
• Mentor Manufacturing Team Leads and Production Technicians
• Establish best practices for integration quality and process discipline
• Drive continuous improvement initiatives across production lines