Director, NPI Operations Engineering

San Mateo, California, United States or Hayward, California, United States
- Full-time

About the Role:

The NPI Operations Engineering leader builds and leads the team responsible for making Skydio's next generation of autonomous robotics, including drones, docks and accessories, at our internal manufacturing facility in Hayward. You’ll deliver the process, manufacturing know-how and technology needed to build the most capable flying robots on the planet. The team combines Manufacturing Design Engineering and Supply Base Engineering into one organization that is 100% focused on new product development.

You will own the manufacturability of every new product: assembly time, assembly yield and the processes, fixtures, equipment and supplier readiness needed to hit them. You and your team will engage with Product Engineering from early architecture, carry products through EVT, DVT and PVT, and hand them to Process Engineering for sustaining once they meet clear production-readiness criteria.

This is a leadership role with significant scope to shape how Skydio develops hardware. You'll set the team's direction, hire and grow engineers, and be the single operations voice in product development. Sustaining engineering for products already in production sits with Process Engineering, so this team stays focused on getting new products right before they reach the line.

How You’ll Make an Impact:

Own the operations engineering development for NPI programs across supply chain and in-house manufacturing

Drive design-for-manufacturing, assembly and serviceability (DFx) input from early architecture onward

Set and commit to assembly time and assembly yield targets for each new product, and track them at every build

Own operations sign-off at product development gates, and elevate manufacturability risks with clear trade-offs

Use PFMEA, DFM reviews and prototype yield, quality and process data to align product design with manufacturing strategy

Identify manufacturing risks early and drive mitigation plans to closure before production ramp

Own the manufacturing plan for new products and major design changes, from prototype through PVT

Define assembly flow, line layout, fixtures and equipment for new products, with labor, cost and capacity estimates that sharpen at each build

Coordinate engineering, design and production validation builds with Product Engineering, Manufacturing, Test and Quality

Define production-readiness and handoff criteria, and lead manufacturing readiness reviews

Develop and continuously improve Skydio's NPI process

Transfer products to Process Engineering with complete documentation, released tooling, and yield and cycle time at target

Own development and validation of assembly processes, including mechanical assembly, electronics integration, adhesive bonding, fastening, soldering and calibration

Own design and qualification of assembly fixtures, error-proofing, and assembly equipment such as dispense systems and torque-controlled drivers

Own the capital budget for new-product assembly fixtures and equipment. Capital for the running production line stays with Manufacturing

Develop process specifications, control plans, component and assembly CTQs, inspections, inline tests, work instructions and manufacturing BOMs, all complete before handoff

Use statistical process control (SPC), capability studies and structured experiments to establish robust process windows

Build a roadmap of core process technologies that future products depend on, such as waterproofing and ingress protection, conformal coatings, sealing and advanced…