Manufacturing Engineer IV - Motor Windings

BLUE ORIGIN•Longmont, CO

12d•$123,611 - $173,055•Onsite

About The Position

This position is part of the Motion Control Business Unit at Honeybee Robotics, which designs, manufactures, and tests motion-control components and integrated solutions for commercial, defense, and space exploration missions. The Manufacturing Engineering Department ensures components and systems meet mission requirements. The Manufacturing Engineer IV will own the development, industrialization, and continuous improvement of manufacturing processes for motor winding and coil assemblies used in electric motors and actuators. The role leads new product integration, taking winding designs from prototype through repeatable, scalable production, and applies high-volume manufacturing discipline in a high-mix, high-reliability aerospace environment. The engineer works alongside technicians and engineers to develop processes, tooling, and work instructions, support production, and resolve non-conformances. The position is based in Colorado. Relocation is provided. The schedule is Monday–Friday on a 5/8 schedule, and interviews include a technical assessment. Applicants must meet the stated U.S. citizenship, permanent residency, refugee, or asylum status requirement. A standard background check is required; additional checks may apply to certain job profiles. The base pay range for Colorado applicants is $123,611.00–$173,054.70; ranges at other sites may differ. Benefits include medical, dental, vision, life and disability insurance, paid parental leave, a 401(k) with company match, education support, stock options for eligible regular employees, paid time off, and company-paid holidays. Depending on role type and job level, employees may also be eligible for bonuses or other benefits; these are not guaranteed.

Requirements

Bachelor of Science in Electrical Engineering, Mechanical Engineering, Manufacturing Engineering, Materials Science, Physics, or a related field, or equivalent experience.
At least 7 years of manufacturing engineering experience with electric motor, stator, rotor, or coil winding processes.
Demonstrated experience with new product introduction, including process development, process validation, and transition from prototype to production.
Experience developing and using process control tools such as PFMEA, control plans, SPC, MSA, and DOE.
Experience operating, diagnosing, and dispositioning non-conforming electromechanical or electrical hardware.
Familiarity with standards such as IPC-A-610, IPC/WHMA-A-620, J-STD-001 with Space Addendum, NASA-STD-8739.4, and NEMA MW 1000, or equivalent automotive quality standards such as IATF 16949, PPAP, and APQP.
Proficiency with 3D CAD programs; SolidWorks or Creo Pro/E preferred.
Experience applying DFMA principles in design development.
Strong communication, organization, and project management skills, including the ability to manage multiple priorities.
Hands-on mindset, strong attention to detail, and ownership of work.
Ability to learn quickly in a fast-paced environment and adapt to new challenges.
Must be a U.S. citizen or national, U.S. permanent resident (current Green Card holder), or lawfully admitted into the U.S. as a refugee or granted asylum.

Nice To Haves

Experience in automotive or other high-volume manufacturing environments developing and producing motor winding products.
Hands-on experience with motor winding technologies and processes, such as needle, flyer, linear, insertion, or hairpin winding; slot liner and insulation installation; lead termination by soldering, welding, brazing, or crimping; varnish, VPI, potting, or encapsulation; and winding electrical testing.
Experience with aerospace, space, or defense motors and electromechanical actuators.
Experience with automated or semi-automated winding equipment, including programming, qualification, and process optimization.
Experience scaling motor winding processes from low-volume prototype to high-rate production.
Experience with hairpin or other advanced winding technologies used in traction or high-performance motors.
Experience with high-reliability or safety-critical hardware.
Experience automating inspection and testing of windings and motor assemblies.
Lean Six Sigma certification at Green Belt level or higher.
Experience with ERP/MES systems and electronic work instruction platforms.

Responsibilities

Lead new product integration for motor winding products, partnering with design engineering from concept through production release to ensure designs are manufacturable, scalable, and cost-effective.
Develop, validate, and document winding processes, including winding methods, coil assembly, lead dressing and termination, lacing, insulation systems, varnish/VPI, potting, and bonding.
Define process parameters and process flows, and conduct process capability studies such as DOE, SPC, Cpk, and MSA.
Specify, design, and qualify winding equipment, fixtures, tooling, and ground support equipment, including semi-automated and automated solutions.
Develop production documentation, including routings, work instructions, process control plans, and PFMEAs.
Define and implement in-process and end-of-line electrical testing for windings, including resistance, inductance, insulation resistance, hipot, surge, and partial discharge testing.
Provide hands-on support to technicians and promptly resolve production issues.
Lead troubleshooting and disposition of non-conforming winding and motor hardware through detailed work instructions.
Drive isolation, containment, and resolution of non-conforming parts and assemblies.
Lead root cause analysis and corrective actions to prevent recurrence of manufacturing and hardware issues.
Apply lean manufacturing and continuous improvement methods to reduce scrap, rework, and cycle time.
Support design and operational gated reviews by contributing technical artifacts and readiness assessments.
Collaborate with design engineering on engineering change requests to improve manufacturability and reduce non-conformances.
Partner with design teams early in development to improve design for manufacture and assembly before design release.
Work with suppliers on materials, magnet wire, insulation systems, and outsourced winding processes as needed.