Director, Process Engineering

Regulus Industries•Dallas, TX

1d•Onsite

About The Position

We are a stealth defense technology startup operating at the intersection of advanced hardware, modern manufacturing, and next-generation AI-enabled manufacturing software. Our mission is to design, build, and deliver real systems that address urgent strategic and industrial capability needs today. The company is fully funded and has confirmed customer demand with orders exceeding projected manufacturing capacity through 2028. Our team combines deep technical expertise across multiple disciplines with the operational rigor required to design, manufacture, deploy, and support systems in demanding real-world environments. Our culture values execution, builders, doers, and ownership. We move quickly, solve hard problems, and take pride in turning ideas into working systems that deliver meaningful results for our customers and mission partners. If you enjoy building real systems and solving hard problems, we would like to learn more about you. Our teams span engineering, manufacturing, supply chain, operations, and software. Together, they design, build, and deploy complex systems that must work reliably in demanding real-world environments. The organization operates with a strong bias toward execution. Engineers work closely with production teams, software interacts directly with hardware and factory systems, and supply chain and logistics ensure that components move efficiently from suppliers to production to delivery. We are seeking a Process Engineering Director to lead the development, qualification, and optimization of robust manufacturing processes for defense-grade components. This hands-on leadership role is critical to delivering mission-critical systems that meet stringent defense standards in a fast-scaling production environment.

Requirements

Bachelor’s degree in Process Engineering, Industrial Engineering, Metallurgy, Materials Science, or Chemical Engineering
7–10+ years in process engineering management, with a proven track record developing and qualifying processes for defense, aerospace, or complex manufacturing/assembly environments (First Article Inspection experience strongly preferred)
Strong proficiency in CpK/PPK analysis, Statistical Process Control (SPC), and RCCA tools (8D, 5-Why)
Hands-on experience with Minitab, Excel, and R-Shiny
Hands-on leader and team builder who thrives in high-pressure, fast-paced environments
Excellent communication skills with the ability to coach, mentor, and proactively solve problems
Ability to stand, walk, and lift up to 50 lbs in a gritty manufacturing shop environment with heat and noise
Must be a U.S. Person due to required access to U.S. export-controlled information or facilities.

Nice To Haves

Deep knowledge of defense standards (MIL-STD, ITAR)
Expertise in metal processing, including heat treating and chemical coatings for ferrous, non-ferrous, and super alloys
Experience with non-destructive testing (NDT) methods such as ultrasonic and dye penetrant for process validation
Six Sigma Black Belt or ASQ Certified Manufacturing Engineer (CMfgE)

Responsibilities

Develop and qualify robust industrial processes for defense-grade steel forgings, ensuring first article compliance with defense standards
Lead first article inspections (FAI) and process validations to deliver battle-ready products
Perform CpK/PpK statistical analysis and utilize root cause tools (8D, 5-Why) to ensure process capability and stability
Apply Statistical Process Control (SPC) and statistical tools (Minitab, Excel, R-Shiny) to maintain tight process control
Leverage deep expertise in metal processing, including heat treating and chemical coatings, to meet demanding defense specifications
Drive Lean and Six Sigma methodologies to optimize processes and eliminate inefficiencies
Serve as the primary process engineering point of contact for customers and suppliers
Lead and develop a team of 4 shift supervisors and multiple process technicians operating across four shifts