Sr Process Engineer

Exo Terra is a world leader in solar electric propulsion systems and space exploration satellites. The company develops Hall Thrusters, propulsion modules, microsatellites and launchvehicleupper stages. We have been awarded multiple propulsion module and satellite contracts.

Position Summary

We are seeking a highly skilled and results-driven Process Engineer to lead the development, industrialization, and ramp-up of manufacturing processes for a new high-rate aerospace production facility. This role is critical in establishing robust, scalable,and efficient processes that meet stringent aerospace quality, cost, and delivery requirements.

The ideal candidate will have deep experience in manufacturing process design, production ramp, and aerospace/precision manufacturing environments, with a strong focus on throughput optimization, quality assurance, and lean principles.

• Lead the design, development, and implementation of manufacturing processes for a new aerospace production site.
• Define and document end-to-end production workflows, including material flow, tooling, equipment, and staffing models.
• Support facility layout planning to optimize throughput, ergonomics, and safety.
• Collaborate with cross-functional teams to ensure readiness for production ramp.

• Develop and validate manufacturing processes, work instructions, and standard operating procedures (SOPs).
• Design and implement process controls to ensure repeatability, quality, and compliance with aerospace standards (e.g., AS9100).
• Select and qualify equipment, tooling, and automation solutions.
• Conduct process capability studies (Cp, Cpk) and establish control plans.

• Lead production ramp-up efforts, achieving target rate, yield, and cost metrics.
• Identify and eliminate bottlenecks to ensure high-rate production throughput.
• Implement lean manufacturing techniques (e.g., takt time, line balancing, value stream mapping).
• Drive continuous improvement initiatives to enhance productivity and reduce waste.

• Ensure processes meet aerospace regulatory and quality requirements.
• Support First Article Inspection (FAI) and qualification builds.
• Partner with Quality teams to resolve non-conformances and root cause investigations.
• Implement error-proofing (poka-yoke) and robust quality controls.

• Develop and track key performance indicators (KPIs), such as yield, cycle time, and OEE.
• Utilize data analytics to identify improvement opportunities.
• Lead Six Sigma / root cause analysis initiatives to improve process stability.

• Work closely with Design Engineering, Supply Chain, Quality, Operations, and Facilities teams.
• Support supplier development and integration of external manufacturing partners.
• Provide technical leadership during design reviews and production readiness assessments.

• Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, or related field.
• 5–10+ years of experience in manufacturing/process engineering, preferably in aerospace or regulated industries.
• Proven experience in launching new production lines or facilities.
• Strong knowledge of high-rate production environments and process scaling.
• Experience with lean manufacturing, Six Sigma, or continuous improvement methodologies.
• Familiarity with aerospace quality systems (AS9100, NADCAP).
• Experience with process validation, PFMEA, control plans, and statistical process control (SPC).

• Excellent verbal and written communication skills
• Experience with Spacecraft Fabrication and Test
• Experience with non-conformance resolution
• E…