Senior Manufacturing Engineer

Zipline•South San Francisco, CA

10h•Onsite

About The Position

Zipline is the world’s largest and most experienced drone delivery service, on a mission to serve all humans equally by ensuring access to food, medicine and essential goods anytime, anywhere. They design, build, and operate the world’s largest autonomous logistics system, making deliveries every 30 seconds across four continents, with millions of deliveries completed. Their system strengthens supply chains, reduces congestion, and provides rapid delivery of critical supplies. Zipline is looking for practical problem solvers who thrive on real-world challenges and rapid growth, motivated by building systems with a direct, meaningful impact on people’s lives. The role involves working on large, integrated electro-mechanical systems from small-scale engineering builds to full-scale production and global deployment. The Senior Manufacturing Engineer will be responsible for designing and scaling multiple in-house final assembly lines for aircraft, zips, docks, and critical feeder sub-assemblies. The goal is to meet growing demand from tens to hundreds of units per week over the next three years, while continuously driving down cost and elevating product quality. This role requires thriving in a fast-paced environment, managing multiple new developments, and quickly aligning teams to drive solutions.

Requirements

7+ years of experience designing and developing manufacturing lines - proven track record of scaling something from the 10s of products per month to the 1000s of products per month.
Bachelors degree in mechanical engineering field or a related field.
Design for Manufacturability (DFM/DFA): Strong understanding of how to influence product design for cost-effective, scalable, and reliable assembly.
Hands-on experience working with products that combine mechanical systems, electronics, and software integration.
Fixture and tooling design: Experience designing and validating custom fixtures, jigs, and tools to support repeatable, ergonomic, and efficient processes.
Manufacturing process validation: Deep knowledge of PFMEA, control plans, process capability (Cp/Cpk), and statistical process control (SPC).
Proficiency in 3D CAD Software (Siemens NX preferred).
Proficient in writing SOPs, work instructions, and process flow documents.
Familiar with statistical tools (e.g., Minitab, JMP, Excel) for analyzing yield, process capability, and production trends.
MES/ERP systems: Experience with manufacturing execution systems and resource planning software to manage production data and operations.
Skilled at identifying root causes and rapidly implementing sustainable corrective actions in a fast-paced environment.
Proven ability to work with design, quality, supply chain, and operations teams to deliver manufacturing outcomes.
Comfortable guiding and reviewing work of junior engineers and technicians.
Strong written and verbal communication skills for documenting processes, presenting data, and aligning teams.
Demonstrated ability to manage complex projects with minimal oversight—from planning through execution and sustainment.
Worked in a super fast-paced environment that is in a constant state of evolution.

Responsibilities

Develop and optimize manufacturing processes and documentation for complex electro-mechanical assemblies, from prototype builds to full-scale production.
Lead planning, budgeting, design, procurement, & commissioning of Assembly Lines and associated facilities & equipment at Zipline for Product Builds
Lead process validation and verification activities, including PFMEAs, capability studies, first article inspections, and pilot builds.
Collaborate closely with design engineers to drive design-for-manufacturability (DFM), ensuring product designs are optimized for reliable and cost-effective assembly.
Own tooling and fixture development, from concept through fabrication, installation, and validation, to support scalable and repeatable manufacturing.
Identify and implement continuous improvement initiatives to improve quality, reduce cycle time, and lower production costs (e.g., lean manufacturing, automation, poka-yoke).
Troubleshoot and resolve production issues, working cross-functionally with quality, design, and maintenance teams to implement corrective and preventive actions.
Support ramp-up of new products and manufacturing lines, coordinating cross-functional activities to ensure smooth transitions from development to production.
Track and analyze manufacturing performance metrics, including first-pass yield, throughput, downtime, and cost of poor quality, to drive data-informed decisions.
Provide technical mentorship to junior manufacturing engineers and technicians, sharing best practices and reviewing designs and process approaches.