Lead Manufacturing Engineer, DFMA - Avionics

Mach Industries • Huntington Beach, CA

19h

About The Position

Mach Industries is hiring a Lead Manufacturing Engineer to provide hands-on technical leadership for design for manufacturing, assembly, and test (DFMA) of avionics for unmanned defense systems. The role focuses on ensuring electronics, harnesses, and avionics boxes can be built, tested, installed, and maintained quickly, reliably, and cost-effectively. The position includes direct reports and responsibility for developing and maintaining the company’s Avionics DFMA guide, establishing design standards, shaping designs early, leading research and development, and supporting production and suppliers.

The engineer will define manufacturing and assembly rules for PCBAs, wire harnesses, connectors, and avionics enclosures; establish connector-retention, mate-assurance, and station-check standards; set design-gate criteria and program DFMA metrics; and train design and manufacturing engineers. They will review vehicle and electrical architecture, conduct virtual assembly studies, establish harness-routing and installation standards, improve ergonomics and build quality, and lead value engineering on released designs.

The role also develops should-cost, cycle-time, and rate models; writes manufacturing requirements for supplier RFQs; and evaluates supplier quotes. R&D work includes automated harness fabrication, flex and rigid-flex circuits, interconnects, potting and coating processes, and automatic connector-mate confirmation. The engineer plans and conducts experiments, builds and tests prototypes, analyzes and publishes results, and co-develops components, processes, and equipment with external partners.

The position assesses contract manufacturers, harness shops, and connector suppliers; supports connector qualification, FMEAs, root-cause investigations, manufacturing trials, and defect prevention; and mentors engineers while helping build Mach’s DFMA function. Candidates must meet the stated U.S. export-control eligibility requirements or be eligible to obtain the necessary authorizations. Extended hours and weekends may be required as needed.

Requirements

• Bachelor’s degree in Electrical, Mechanical, Manufacturing, or Industrial Engineering, or equivalent.
• At least 8 years of experience in avionics, PCBA, or harness manufacturing or design engineering.
• Experience taking hardware from design into rate production in aerospace, defense, automotive, or consumer electronics.
• Working knowledge of IPC-A-610, J-STD-001, and IPC/WHMA-A-620.
• Experience with SMT processes, box build, and electrical test.
• Track record of writing design standards, guides, or process specifications.
• Strong manufacturing and industrial engineering fundamentals, including cycle-time analysis, OEE, process capability (Cp/Cpk), gauge R&R, DOE, error proofing, ergonomics, and ROI.
• Working knowledge of GD&T (ASME Y14.5) and tolerance stack-ups.
• Skill in 3D CAD tools such as NX, CATIA, or SolidWorks, or similar, and comfort using ECAD tools.
• Available to work extended hours and weekends as needed.
• Must be a U.S. citizen or national, lawful permanent resident, refugee, or asylee, or eligible to obtain required U.S. Department of State authorizations for export-controlled work.

Nice To Haves

• Master’s degree in Electrical Engineering or a related field.
• Knowledge of automotive connector standards such as SAE/USCAR-2 and USCAR-25 and MIL-spec connectors such as MIL-DTL-38999.
• Experience with automotive high-volume harness and connector systems.
• Experience ruggedizing defense electronics to MIL-STD-810, including shock and vibration.
• IPC CIS or CIT certification.
• Experience in both high-rate automotive or consumer electronics production.
• Formal DFMA methods, such as Boothroyd Dewhurst; should-cost modeling; and value engineering programs with measured savings.
• Experience leading DFMEAs and PFMEAs.
• Patents, publications, or processes developed and put into production.
• Experience in an AS9100 or defense production environment.
• Lean or Six Sigma certification.

Responsibilities

• Write, publish, maintain, and update Mach’s Avionics DFMA guide, incorporating design rules, preferred components and processes, standard features and tolerances, examples, checklists, test results, production lessons, and supplier input.
• Define DFM, DFA, and DFT rules for PCBAs, wire harnesses, connectors, and avionics enclosures.
• Set connector retention and mate-assurance standards, including CPA and TPA features, full-mate indicators, and limits on mating and CPA engagement force.
• Define station-level connection checks, including push-pull-push checks, vision checks of CPA position, and electrical continuity or mate-detect tests.
• Set DFMA sign-off criteria for design gates and ensure programs follow them.
• Set and track program DFMA metrics, including part and connector counts, assembly and test time, first-pass yield, and cost.
• Train design and manufacturing engineers to apply the DFMA guide.
• Review vehicle and electrical architecture early, including box placement, harness layout, and connector strategy.
• Lead virtual static and kinematic assembly studies; assess harness routing, installation paths, and hand and tool access for connector mating and CPA seating.
• Establish harness routing, retention, and installation rules; drive content reduction, simpler assembly, build-in-quality, ergonomic access, and automation-suitable features.
• Define avionics poka-yoke standards, such as connector keying and clocking, unique connectors per interface, CPA and TPA features, and blind-mate or tool-less installation.
• Lead value engineering on released designs by challenging assumptions and reducing cost.
• Build should-cost, cycle-time, and rate models showing how design choices affect cost, capital investment, schedule, and quality.
• Write manufacturing requirements for RFQ packages and help evaluate supplier quotes.
• Lead R&D in automated harness fabrication, flex and rigid-flex circuits, simpler interconnects, faster-curing potting and coatings, and automatic full-mate confirmation methods.
• Plan and conduct designed experiments; build test articles, test to failure, analyze results statistically, and publish findings.
• Co-develop components, processes, and equipment with suppliers, contract manufacturers, equipment makers, universities, and national labs.
• Lead manufacturing trials during prototype and validation builds to prove new processes.
• Assess contract manufacturers, harness shops, and connector suppliers on site, encouraging best practices and lower investment.
• Work with connector suppliers on CPA and TPA design and qualification.
• Provide avionics expertise for DFMEAs and PFMEAs and maintain a library of failure modes and proven controls.
• Lead root-cause analysis of escapes and repeat defects, and feed corrective actions into the DFMA guide.
• Mentor engineers and help build Mach’s DFMA function.

Benefits

• Performance-based incentives and bonus structure tied to individual and company performance.
• Stock options or equity participation; competitive equity grants are included in most offers.
• Healthcare and health insurance.
• Dental insurance.
• Vision insurance.
• Retirement savings and retirement plans.
• Paid time off.
• Funds for continuing education, training, and career growth.

What This Job Offers

• Job Type: Full-time
• Career Level: Senior