Staff Manufacturing Engineer

About the role

As a Manufacturing Engineer at Firehawk Aerospace, you will play a critical role in developing, optimizing, and supporting manufacturing processes for our rocket motor systems. You will work closely with design, quality, and production teams to ensure efficient, high-quality, and scalable manufacturing operations. This position requires a hands-on approach to problem-solving, a strong understanding of manufacturing principles, and a commitment to continuous improvement.

Responsibilities

• Develop, implement, and optimize integration and manufacturing processes for the production of rocket motor systems, ensuring efficiency, quality, and safety.
• Collaborate with design engineering teams to ensure manufacturability of integration of components and assemblies, providing Design for Manufacturing and Assembly (DFMA) feedback during the development phase.
• Create and maintain detailed work instructions, process documentation, and manufacturing plans to support production and hardware integration activities.
• Identify and implement process improvements to enhance overall production efficiency.
• Establish and equip a facility to perform Lot Acceptance Testing (LAT) and support ongoing LAT activities, ensuring compliance with quality and performance standards.
• Support the design, procurement, and implementation of manufacturing tools, fixtures, and equipment to meet production requirements.
• Lead root cause analysis and corrective action efforts for production issues.
• Develop and execute validation and qualification plans for new processes, equipment, and materials.
• Collaborate with quality engineering to ensure compliance with industry standards, customer requirements, and internal quality systems.
• Support the implementation of automation and advanced manufacturing technologies into manufacturing processes.
• Assist in generation of key performance indicators (KPIs) such as cycle time, scrap rates, and downtime, and develop strategies to improve performance.
• Support proposal development as required.
• Ensure compliance with safety, environmental, and regulatory requirements in the manufacturing environment.

Requirements

• Bachelor’s degree in Manufacturing, Industrial, Mechanical, or Aerospace Engineering, or a related field.
• 8+ years of experience in manufacturing engineering, process development, or production support in aerospace, defense, or a related industry.
• Strong ownership mentality and ability to lead new product manufacturing design processes flow.
• Experience with manufacturing process documentation, including work instructions, process flow diagrams, and control plans.
• Strong understanding of manufacturing principles, including lean manufacturing, Six Sigma, and Design for Manufacturing and Assembly (DFMA).
• Familiarity with 3D modeling software (PTC Creo/Windchill or equivalent).
• Proficiency with Product Lifecycle Management (PLM) systems (Deltek Costpoint or equivalent).
• Strong problem-solving skills and the ability to perform root cause analysis and implement corrective actions.
• Excellent communication and collaboration skills, with the ability to work effectively in cross-functional teams.
• Ability to obtain and maintain a DOD issued security clearance.
• Ability to travel (up to 10%).

Preferred Qualifications

• Experience with process design optimization and capacity modeling.
• Experience with automation and robotics in manufacturing processes.
• Experience with compression molding.
• Working knowledge of Mil-Std-4145 (explosive safety).
• Experience in the manufacturing of rockets or weapon systems and components.
• Experience with Enterprise Resource Planning (ERP) systems for production planning and inventory management.
• Familiarity with additive manufacturing (3D printing) processes and their application in production environments.
• Knowledge of non-destructive testing (NDT) methods and quality assurance practices.
• Experience transitioning products from development to production.
• Certification in lean manufacturing, Six Sigma, or related methodologies.

Benefits

• Health Coverage: 100% employer-paid medical premiums for employees and up to 75% coverage for dependents under select plans, with additional options for PPO and HDHP plans. Coverage begins the first of the month following your hire date.
• Dental and Vision Plans: Affordable dental and vision plans with extensive coverage options, including preventive care, orthodontics, and allowances for contacts and frames.
• Flexible Work Schedule: 9/80 schedule option, allowing for greater flexibility and work-life balance.
• On-Site Perks: Complimentary snacks and refreshments to keep you energized throughout the day.
• Professional Growth: Mentorship opportunities with industry-leading engineers and engagement in cutting-edge projects at the forefront of aerospace innovation.