Senior Program Manager, Production & Manufacturing — NGCM

AeroVironment•Huntsville, AL

About The Position

AeroVironment is seeking an experienced production and manufacturing leader to lead the Next Generation Counter-UAS Missile (NGCM) program’s transition from prototype development through initial production and full-rate production. The role establishes and executes manufacturing strategy, builds production capability, and aligns internal operations and critical suppliers to meet program cost, schedule, quality, and capacity requirements. It calls for hands-on leadership of complex defense hardware production transitions, including evolving designs, supplier constraints, manufacturing readiness, and increasing delivery commitments, and the ability to turn development hardware into a repeatable, scalable, and affordable production system. The position owns the production transition plan and readiness process; develops repeatable manufacturing operations; builds supplier and capacity readiness; manages production performance; and defines and leads the production organization. It includes coordinating across engineering, supply chain, quality, operations, and program management, and providing production status, risks, recovery actions, and investment recommendations to senior leadership. Initial success measures include assessing internal and supplier manufacturing readiness, delivering an accountable production transition plan, establishing a performance dashboard and recurring reviews, and identifying constraints to initial deliveries and production growth within the first 90 days. Within 6–12 months, the role is expected to establish controlled, repeatable production and acceptance processes, demonstrate capacity readiness, improve build predictability, yield, and recurring unit-cost performance, and execute staffing, supplier, tooling, and capital actions for the next production ramp. The role requires access to ITAR- and/or EAR-controlled information. Applicants must qualify as a U.S. person under those regulations or be eligible for an export license; some positions may require current U.S. citizenship due to contract requirements. The position may require travel to suppliers, manufacturing facilities, and other program locations as needed.

Requirements

Bachelor’s degree in engineering, manufacturing, operations management, or a related discipline, or an equivalent combination of education and relevant experience.
Ten or more years of relevant aerospace or defense manufacturing experience, including leadership of complex hardware production.
Demonstrated success personally leading at least one program from prototype or engineering development into repeatable production with increasing delivery rates.
Experience establishing production readiness, manufacturing processes, tooling, staffing, and supplier capacity.
Experience managing production schedules, manufacturing budgets, recurring unit costs, and capital requirements.
Working knowledge of configuration management, engineering change control, material planning, ERP/MRP systems, and production quality systems.
Demonstrated ability to resolve production constraints across engineering, supply chain, quality, and program management.
Strong communication skills and experience presenting production performance, risks, and recovery plans to senior leaders.
Ability to travel to suppliers, manufacturing facilities, and other program locations as required.
Must qualify as a U.S. person under ITAR/EAR or be eligible for an export license; some positions may require current U.S. citizenship due to contract requirements.

Nice To Haves

Experience transitioning missile, interceptor, munition, or comparable complex defense hardware programs into production.
Experience supporting accelerated fielding programs while establishing sustainable production capability.
Experience with manufacturing readiness assessments, production readiness reviews, first article inspections, and AS9100 environments.
Experience scaling assembly and acceptance-test operations across internal facilities and multiple suppliers.
Lean manufacturing, Six Sigma, or comparable continuous improvement experience.
Experience developing capital investment business cases and executing manufacturing facility expansion.

Responsibilities

Own and execute an integrated production transition plan covering manufacturing readiness, facilities, equipment, tooling, staffing, materials, suppliers, quality, and acceptance testing.
Establish measurable entry and exit criteria for prototype builds, pilot production, initial production, and full-rate production.
Lead manufacturing readiness assessments and production readiness reviews, assigning and closing actions before they affect delivery commitments.
Integrate production milestones, material availability, and capacity constraints into the program’s integrated master schedule.
Develop production flows, assembly planning, work instructions, tooling, test equipment, and workforce training.
Partner with engineering to improve producibility, assembly efficiency, testability, and affordability.
Establish configuration-controlled build processes, product traceability, and disciplined incorporation of engineering changes.
Define the handoff from engineering-led development builds to manufacturing-led production execution.
Ensure production plans incorporate applicable safety, handling, and facility requirements.
Partner with supply chain, subcontracts, engineering, and quality to assess critical supplier readiness and delivery performance.
Validate supplier capacity, long-lead material requirements, tooling readiness, and recovery plans.
Develop make-or-buy recommendations and identify alternate sources or internal capability needs.
Build phased capacity plans supported by equipment, labor, floor space, test throughput, capital investment, and supplier commitments.
Own manufacturing execution against approved delivery schedules, budgets, and quality objectives.
Establish production metrics for throughput, first-pass yield, rework, scrap, labor efficiency, material shortages, and on-time delivery.
Lead resolution of manufacturing issues and coordinate corrective actions across engineering, quality, suppliers, and operations.
Develop recurring unit-cost estimates and execute cost-reduction initiatives as production volume increases.
Provide production status, risks, recovery actions, and investment recommendations to program and executive leadership.
Define the manufacturing organization, staffing plan, and skill requirements for each production phase.
Lead and develop manufacturing engineers, production supervisors, planners, technicians, and other assigned personnel.
Establish accountability across program management, engineering, manufacturing, quality, and supply chain.
Build a culture of safety, quality, disciplined execution, and continuous improvement.
Complete a baseline assessment of internal and supplier manufacturing readiness within the first 90 days.
Deliver an integrated production transition plan with accountable owners, milestones, resource requirements, and key risks within the first 90 days.
Establish a production performance dashboard and recurring execution reviews within the first 90 days.
Identify priority constraints to initial deliveries and sustained production growth within the first 90 days.
Establish controlled, repeatable production and acceptance processes and demonstrate capacity readiness against approved commitments within 6–12 months.
Improve build predictability, first-pass yield, and recurring unit-cost performance, and execute staffing, supplier, tooling, and capital actions for the next production ramp.