Senior Manufacturing Engineer

About the role

SAIC is seeking a Senior Manufacturing Engineer in Middletown, RI to oversee the fabrication of Electro-Mechanical Systems, responsible for managing and optimizing manufacturing processes to ensure delivery of high-quality, cost-effective, and reliable products. The role requires close collaboration with design engineers to ensure manufacturability, development of efficient production workflows, and management of materials, tools, and equipment. They drive continuous improvement initiatives focusing on efficiency, cost reduction, and scalability while maintaining safety standards and aligning project timelines. Effective communication, technical expertise, and leadership are critical to bridging design, production, and quality objectives. The position is on‑site with occasional travel (approximately 10% of the time).

Responsibilities

• Develop, implement, and optimize manufacturing processes to ensure high-quality, repeatable, and cost-effective fabrication of the electro‑mechanical system.
• Develop and document standard operating procedures (SOPs) and work instructions tailored to the fabrication of electro‑mechanical assemblies.
• Work closely with design engineers to ensure manufacturability (Design for Manufacturability – DFM).
• Participate in design reviews to provide feedback on design elements that impact fabrication processes, including material selection, tolerances, and assembly layouts.
• Communicate effectively with designers to address design changes, prototype testing, and improvements to the system.
• Develop manufacturing plans, schedules, and resource allocation to meet production timelines while adhering to cost and quality objectives.
• Oversee and direct the work of technicians or production personnel on the shop floor to ensure proper fabrication practices are followed.
• Maintain documentation for all processes, including traceability for components, inspection data, and testing results.
• Design, develop, and procure tools, jigs, and fixtures required for fabrication of the electro‑mechanical system.
• Implement inspections and functional testing processes at critical stages to verify compliance with quality specifications; review inspection results, investigate product deficiencies, and initiate corrective actions.
• Troubleshoot and address fabrication, assembly, and performance issues that occur during production.
• Perform cost analysis and budgeting for materials, equipment, and labor associated with the fabrication process; identify opportunities for cost reduction (process improvements, alternative materials, outsourcing).
• Ensure all manufacturing processes adhere to required safety protocols and standards.
• Analyze performance data, monitor key performance indicators (KPIs), and lead efforts for continuous process improvement.
• Maintain accurate and up‑to‑date documentation throughout the fabrication lifecycle, including engineering drawings, assembly instructions, test results, and process maps.
• Report progress, challenges, and improvement opportunities to management through regular updates and presentations.
• Design and arrange work cell layouts within plant facilities to ensure efficiency and productivity.

Qualifications

• Bachelor’s degree in an engineering discipline with at least five (5) years of experience; equivalent experience may be accepted in lieu of a degree.
• Must be a U.S. Citizen.
• Background in managing manufacturing process development, particularly in assembly, machining, and testing of electro‑mechanical systems.
• Excellent organizational skills and attention to detail with the ability to perform multiple tasks and obtain timely results.
• Excellent communication and project management skills to coordinate with cross‑functional teams.
• Experience leading and mentoring other technical professionals preferred.
• Must be able to obtain a Secret security clearance.
• Ability to read, interpret, and create assembly and component drawings, engineering specifications, and electrical schematics.
• Ability to use a variety of precision measuring tools, including multimeters, electrical test equipment, micrometers, calipers, and other metrology devices.
• Proficient in MS Office software (Word, Excel, Outlook, PowerPoint).
• Proficiency in tools such as CAD (SolidWorks, CREO, or similar), ERP systems, and simulation software.

Schedule

Full‑Time, Day shift. Travel required approximately 10% of the time.