Manufacturing Process Flow & Control DFX Engineer III (Subsystem)

Blue Origin • Cupertino, CA

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About The Position

At Blue Origin, we envision millions of people living and working in space for the benefit of Earth. We’re working to develop reusable, safe, and low-cost space vehicles and systems within a culture of safety, collaboration, and inclusion. Join our team of problem solvers as we add new chapters to the history of spaceflight! This role is part of Blue Origin Operations, which is comprised of Integrated Supply Chain, Test Operations, Safety, Quality, and Mission Assurance. This includes Manufacturing and Supply Chain support across all Blue Origin facilities. At Blue Origin, we believe in the power of manufacturing excellence to make space accessible and to benefit Earth. We are seeking a talented Manufacturing Process Flow & Control DFX Engineer to join our team and own the architecture, integration, and end-to-end control of our manufacturing lines. You will serve as the critical link between individual manufacturing cells, ensuring seamless flow, traceability, and verification across the entire production system — from raw material entry to final product delivery. This is a uniquely cross-functional role requiring both a systems-thinking mindset and deep manufacturing engineering expertise. You will influence how rockets and spacecraft are built, ensuring every process step is intentional, controlled, measurable, and verified.

Requirements

• Bachelor's degree in Mechanical Engineering, Aerospace Engineering, Industrial Engineering, Manufacturing Engineering, or a related technical field
• 5+ years of experience in manufacturing engineering, production systems, or process engineering in an aerospace, defense, automotive, or high-complexity manufacturing environment
• Demonstrated experience designing or improving end-to-end manufacturing flows with multiple interconnected process steps
• Working knowledge of process control methodologies — Control Plans, PFMEA, SPC, CPK analysis
• Experience defining or implementing verification and test strategies within a production environment
• Strong understanding of Lean Manufacturing principles — flow, pull, takt, waste elimination, value stream mapping
• Proven ability to work cross-functionally across engineering, quality, operations, and supply chain
• Strong analytical and problem-solving skills with a data-driven approach to decision-making

Nice To Haves

• Master's degree in Engineering or Manufacturing Systems
• Experience with propulsion systems, structures, avionics, or fluid systems manufacturing
• Hands-on experience with MES platforms (e.g., Solumina, SAP ME, Sight Machine, or similar)
• Familiarity with digital twin or simulation tools for manufacturing (e.g., Siemens Plant Simulation, Arena, or similar)
• Experience with automated test systems and functional test development for complex hardware
• Knowledge of AS9100, AS9102 (FAI), and NASA/DoD manufacturing standards
• Lean Six Sigma Green Belt or Black Belt certification
• Experience in a high-mix, low-volume manufacturing environment with serialized hardware traceability requirements
• Familiarity with Model-Based Definition (MBD) and Model-Based Enterprise (MBE) environments

Responsibilities

• Design and own the end-to-end manufacturing process flow, defining how individual manufacturing cells are physically and logically connected to form a complete production line
• Develop and maintain Value Stream Maps (VSMs) and Process Flow Diagrams (PFDs) that represent the full material and information flow across the production system
• Establish manufacturing cell interfaces — defining inputs, outputs, handoff criteria, and interdependencies between cells
• Lead Design for Manufacturability (DFM), Design for Assembly (DFA), and Design for Testability (DFT) reviews to ensure products and processes are optimized for flow and control
• Identify and eliminate bottlenecks, waste, and flow disruptions using Lean manufacturing principles and systematic analysis
• Define and implement process control strategies at the line level, ensuring that critical process parameters (CPPs) and critical quality attributes (CQAs) are monitored and controlled across all cells
• Develop Control Plans and Process Control Documents (PCDs) that span the entire manufacturing line, not just individual operations
• Establish inter-cell control gates — defining hold/release criteria that must be satisfied before work-in-progress (WIP) moves between manufacturing cells
• Partner with Manufacturing Engineering, Quality, and Automation teams to implement Statistical Process Control (SPC) and real-time monitoring solutions at the line level
• Drive first-pass yield improvement and escape prevention through proactive process control strategies
• Define the test coverage matrix, mapping product requirements and process risks to specific test and inspection points throughout the production flow
• Partner with Test Engineering to design in-process verification stations, functional test sequences, and acceptance test procedures (ATPs) that are integrated into the line flow
• Ensure test data traceability — all test results, process data, and verification records are captured, linked to serialized hardware, and accessible for downstream decision-making
• Lead the development of Go/No-Go criteria and accept/reject disposition workflows at each verification gate within the line
• Drive DFT (Design for Testability) initiatives with product design teams to improve test access, observability, and controllability
• Partner with Manufacturing IT and Digital Engineering teams to implement Manufacturing Execution System (MES) workflows that enforce process sequencing, capture verification data, and flag non-conformances
• Ensure end-to-end serialization and traceability of hardware, materials, and process records from first operation to final acceptance
• Leverage manufacturing data to perform line health analytics, identifying systemic issues before they result in escapes or delivery impacts
• Engage with product design teams early in the development lifecycle to influence design decisions through the lens of manufacturability, flow efficiency, and testability
• Lead formal DFX reviews (DFM, DFA, DFT, DFI, DFC) at key program milestones (PDR, CDR, PRR, MRR)
• Identify design features that create flow disruptions, rework loops, or untestable conditions, and drive design changes to resolution
• Champion the use of digital twins and virtual factory simulations to model and validate line flow prior to physical implementation
• Drive continuous improvement initiatives targeting line throughput, flow efficiency, first-pass yield, and test cycle time
• Develop and maintain line performance dashboards tracking key metrics: takt adherence, WIP levels, yield by cell, test pass rates, and escape metrics
• Support root cause analysis (RCA) and corrective action for systemic line-level issues

Benefits

• Medical, dental, vision, basic and supplemental life insurance, paid parental leave, short and long-term disability, 401(k) with a company match of up to 5%, and an Education Support Program.
• Stock Options for all regular employees (working at least 20 hours/week)
• Paid Time Off: Up to four (4) weeks per year based on weekly scheduled hours, and up to 14 company-paid holidays.

What This Job Offers

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