Manufacturing & Coatings Scale-Up Lead

Booz Allen Hamilton•Lorton, VA

2d•$62,000 - $141,000•Onsite

About The Position

Designs and implements new technologies, systems, and processes to improve plant production and efficiency. Applies advanced skills, extensive technical expertise, and full industry knowledge to develop innovative solutions to complex problems. Works without considerable direction and mentors and may supervise team members. The role focuses on transitioning coating and materials processes from laboratory or prototype settings to pilot or production-scale manufacturing. It includes conducting manufacturing trials, process development, troubleshooting, root-cause analysis, and evaluating processes for repeatability, yield, throughput, quality, and scalability. The lead works across R&D, process engineering, quality, manufacturing, and suppliers to translate technical coating requirements into repeatable processes, work instructions, process specifications, and acceptance criteria. The position is onsite in Lorton, Virginia (Remote Work: No). Applicants selected will be subject to a security investigation and may need to meet eligibility requirements for access to classified information. The projected annualized compensation range is $62,000 to $141,000 USD.

Requirements

Experience in a coatings, materials processing, manufacturing engineering, or process engineering environment.
Experience transitioning processes from laboratory or prototype environments to pilot or production-scale manufacturing.
Experience conducting manufacturing trials, process development, troubleshooting, and root-cause analysis for coating-related defects or process variability.
Experience evaluating manufacturing processes for repeatability, yield, throughput, quality, and scalability.
Experience with cross-functional leadership across R&D, process engineering, quality, manufacturing, and suppliers.
Ability to translate technical coating requirements into repeatable manufacturing processes, work instructions, process specifications, and acceptance criteria.
Ability to obtain a Secret clearance.
Bachelor's degree in Chemical Engineering, Materials Science, Materials Engineering, Mechanical Engineering, Manufacturing Engineering, Biomolecular Engineering, or Chemistry.

Nice To Haves

Experience supporting the transition of novel or emerging material technologies into commercial products.
Experience in defense, aerospace, advanced manufacturing, automotive, industrial, or other highly controlled production environments.
Experience with quality and performance control, including developing and validating specifications for thickness, uniformity, adhesion, curing and drying profiles, and defect rates.
Experience establishing and controlling critical coating process parameters, including surface preparation, viscosity, coating thickness, application rate, temperature, cure conditions, and environmental conditions.
Knowledge of material behavior analysis, including how substrates, binders, solvents, and additives behave when moving from small to large scale.
Knowledge of coating application processes and equipment, including spray, roll, dip, flow, slot-die, or comparable deposition methods.

Responsibilities

Design and implement new technologies, systems, and processes to improve plant production and efficiency.
Transition processes from laboratory or prototype environments to pilot or production-scale manufacturing.
Conduct manufacturing trials, process development, troubleshooting, and root-cause analysis for coating-related defects or process variability.
Evaluate manufacturing processes for repeatability, yield, throughput, quality, and scalability.
Lead cross-functional work involving R&D, process engineering, quality, manufacturing, and suppliers.
Translate technical coating requirements into repeatable manufacturing processes, work instructions, process specifications, and acceptance criteria.
Mentor and potentially supervise team members.