Manufacturing Engineer

Ursa Major•Berthoud, CO

35d•$76,000 - $94,000

About The Position

As a Manufacturing Engineer focused on NPI and production readiness, you will be the architect of the production ecosystem. You will bridge the gap between initial hardware design and full-rate production by designing, simulating, and implementing world-class manufacturing systems. Your mission is to ensure that every subcomponent has a defined, validated path to flight/delivery, minimizing waste and maximizing OEE (Overall Equipment Effectiveness) through rigorous Value Stream Mapping, DFM collaboration, and data-driven line balancing.

Requirements

B.S. in Mechanical, Aerospace, or Industrial Engineering (or equivalent experience).
Proven track record in NPI (New Product Introduction) within high-complexity industries (e.g., Aerospace, Automotive, Medical Devices).
Proficiency in CAD (for layout design) and production simulation software.
Deep understanding of Lean Manufacturing, Six Sigma, and KANBAN signaling.
Experience with Value Stream Mapping and Mixed Model line balancing.
Exceptional negotiation skills to bridge the gap between design engineering and production technicians.

Responsibilities

Manufacturing Systems Design & Simulation Value Stream Mapping (VSM): Define the end-to-end process flow for hardware, accounting for technical validation, cycle times, resource allocation, and equipment requirements.
Factory Layout & Flow: Design production layouts that prioritize hardware flow and minimize wasted movement, ensuring all facility needs, safety standards, and industry requirements are documented and met.
Modeling & Simulation: Input production line data into simulators to visualize flow, identify potential bottlenecks, and mitigate risks to the manufacturing system before physical implementation.
Signaling & Logistics: Perform the mathematical calculations to balance production lines; design and implement IPKs, RIPs, KANBAN systems, and visual signaling strategies.
Design for Manufacturability (DFM) & Collaboration Design Integration: Collaborate with Design, Quality, and Systems teams to ensure manufacturability is "baked into" the hardware at the earliest stages.
Requirement Advocacy: Negotiate between design intent and manufacturing capability to ensure all hardware requirements are clearly stated on drawings and feasible for the production line.
Risk Mitigation: Identify specific design-based risks to the manufacturing system and prioritize mitigation strategies during the production readiness phase.
Production Readiness & "Burst Build" Execution Resource Planning: Define immediate needs for personnel, custom tooling, and equipment per workstation to feed into hiring plans and facilities updates.
Mixed Model Strategy: Incorporate manufacturing actions into mixed-model calculations to define the resources needed for varied product throughput.
Workstation Architecture: Transition "Burst Build" learnings into permanent workstation designs, including shadow boards, specialized lighting, validation methods, and ergonomic considerations.
Documentation: Author and refine high-fidelity Work Instructions (WIs) based on iterative learnings from development builds.
Continuous Improvement & Off-Nominal Planning Rework & Off-Line Strategy: Define "off-nominal" plans to accommodate hardware rework without downing the main production line.
Bottleneck Optimization: Continuously track production bottlenecks and consistent rework areas to enforce process improvements and validation testing.
Change Management: Establish and prioritize methods to document, track, and enforce system changes based on risk priority, ensuring visibility across the organization.