Sr. Manufacturing Process Flow & Control DFX Engineer

Sr. Manufacturing Process Flow & Control DFX Engineer Own end-to-end manufacturing process flow and control design for Tera Wave production

Location:

San Francisco, California

Compensation: $156, USD / year

At Blue Origin, we envision millions of people living and working in space for the benefit of Earth. We're working to develop reusable, safe, and low-cost space vehicles and systems within a culture of safety, collaboration, and inclusion. Join our team of problem solvers as we add new chapters to the history of spaceflight!

This role is part of Blue Origin Operations, which is comprised of Integrated Supply Chain, Test Operations, Safety, Quality, and Mission Assurance. This includes Manufacturing and Supply Chain support across all Blue Origin facilities.

Blue Origin's Emerging Systems business unit is building Tera Wave, a satellite communications constellation powered by the most advanced optical communications architecture ever attempted: thousands of optically interconnected satellites delivering symmetrical data speeds of up to 6 Tbps anywhere on Earth, providing enterprise and hyperscale customers with resilient, scalable connectivity for critical operations where terrestrial infrastructure cannot reach.

As a Senior Manufacturing Process Flow & Control DFX Engineer, you will own the end-to-end manufacturing process flow and process control design integration for Tera Wave production — bridging production line architecture, process control systems, and volume production readiness. As a foundational element of Tera Wave operations, hardware must be produced through process flows architected not only for throughput but for manufacturability, testability, reliability, and serviceability at constellation scale.

This is a hands-on role for an engineer who has designed, optimized, and scaled complex manufacturing process flows and control systems in fast-moving, high-volume manufacturing environments and wants to apply that experience to hardware operating at orbital scale.

Special Mentions:

• Relocation assistance is available for qualified candidates.
• Travel:
  Up to 50%.

• Lead manufacturing process flow design for satellite modules and subsystems: production line architecture, workflow sequencing, station design, takt time optimization, and material flow.
• Own process control development — including statistical process control (SPC), process monitoring, traveler and work instruction systems, MES integration, and data collection workflows — to ensure robust, repeatable production.
• Manage process documentation, routing definition, capacity planning, vendor and internal coordination, and production line oversight.
• Drive process validation, control plan development, first-article and production readiness reviews to support production ramp.

• Drive Design for Excellence (DFX) principles — DFM, DFT, DFA, DFR, and DFS — across the full manufacturing process flow and control lifecycle to ensure hardware scales from prototype through volume production for Tera Wave operations.
• Design for Manufacturability (DFM):
  Optimize process sequencing, station layout, and workflow design to maximize yield, throughput, and minimize cost at constellation-scale production volumes.
• Design for Test (DFT):
  Architect in-line test and inspection points, data capture, and process monitoring to enable efficient factory acceptance, traceability, and in-field diagnostics.
• Design for Assembly (DFA):
  Simplify process steps, minimize handoffs, and optimize station design to reduce cycle time, rework, and error rates across the line.
• Design for Reliability (DFR):
  Apply process FMEA, control plans, statistical process…