Senior NPI Manufacturing Engineer

Position Summary

The Sr. NPI Manufacturing Engineer will lead the development, validation, and industrialization of manufacturing processes to support the successful introduction of new UAV systems into production within the aerospace and defense sector. This role is responsible for owning New Product Introduction (NPI) from early design phases through production ramp, ensuring designs are optimized for manufacturability, scalability, quality, and cost.

Essential Duties And Responsibilities

• Lead NPI efforts from concept through production ramp, including EVT, DVT, PVT, and LRIP phases.
• Own manufacturing readiness, ensuring processes, tooling, documentation, and training are in place for successful product launches.
• Drive DFM/DFA/DFT reviews with design engineering to ensure scalable, cost-effective, and high-quality product designs.
• Develop, validate, and implement manufacturing and test processes for new UAV systems.
• Design, procure, and validate jigs, fixtures, tooling, and automation solutions to support production efficiency and repeatability.
• Serve as the primary manufacturing point of contact for new product programs, ensuring alignment across cross-functional teams.
• Support prototype builds and production ramp by troubleshooting issues, reducing variability, and improving yield and throughput.
• Lead root cause analysis and corrective actions for design and process-related issues during NPI phases.
• Develop and maintain manufacturing documentation including work instructions, SOPs, PFMEAs, control plans, and build plans.
• Drive implementation of Lean Manufacturing principles such as 5S, value stream mapping, standard work, and Kaizen events.
• Perform time studies, capacity planning, and cost analysis to support production scalability and resource planning.
• Integrate automation, advanced manufacturing technologies, and Industry 4.0 solutions into new product lines.
• Ensure compliance with AS9100, ISO, ITAR, and other aerospace/defense regulatory requirements.
• Mentor junior engineers and provide technical leadership across NPI initiatives.
• Perform other duties as assigned

Required Qualifications

• Bachelor’s degree in Manufacturing Engineering, Mechanical Engineering, Industrial Engineering, or related field.
• 7–12+ years of experience in aerospace manufacturing engineering, with a strong focus on New Product Introduction (NPI), preferably in UAV, aerospace, defense, or high-precision manufacturing environments.
• Deep expertise in NPI processes including EVT, DVT, PVT, and production ramp.
• Strong knowledge of manufacturing methods (composites, machining, assembly, automation).
• Advanced proficiency in DFM/DFA/DFT methodologies.
• Experience with CAD and manufacturing systems (e.g., SolidWorks, AutoCAD, ERP/MRP).
• Strong understanding of process validation, PFMEA, control plans, and SPC.
• Excellent problem-solving, data analysis, and root cause investigation skills.
• Ability to interpret complex engineering drawings, specifications, and aerospace standards.
• Strong cross-functional leadership and project management capability.
• Ability to operate effectively in fast-paced, high-growth environments.

Additional Desired Qualifications

• Leverage Lean Six Sigma Green Belt or Black Belt, preferred.
• PMP (Project Management Professional), preferred.
• Experience leading full product lifecycle industrialization in aerospace or defense.
• Strong background in automation and Industry 4.0 implementation.
• Proven ability to drive successful product launches from prototype to production.
• Familiarity with AS9100, IPC standards, ISO9001, MIL-STD, and FAA guidance.
• Experience mentoring and developing engineering teams.