Sr. Manager, Industrial Engineering

Archer Aviation•San Jose, CA

47d•Onsite

About The Position

This role will be based at Archer's headquarters in San Jose, California. What You'll Do: Lead the Industrial Engineering (IE) organization responsible for defining, standardizing, and optimizing systems globally across Archer's engineering, manufacturing, and supply chain. Build and develop a high-performing team of Industrial Engineers focused on process design, capacity analysis, layout optimization, and lean implementation. Own the development of Manufacturing System Design (MSD) - ensuring seamless integration of people, machines, materials, and information through all phases: plan, design, validate, and improve. Drive the standardization of IE methodologies, including: Standardized Work Instructions (SWI), Work Combination Tables (WCT), and Standard Operation Sheets (SOS). PFEP (Plan for Every Part), containerization, and parts presentation planning in partnership with Logistics. Value Stream Mapping (VSM), EPEI analysis, OEE calculation, and capacity studies to identify bottlenecks and improvement opportunities. Oversee plant and warehouse layout design, including space utilization studies, storage systems, and material flow paths that tie directly to CapEx and operational efficiency. Design warehouse and lineside material flow systems, including kitting strategies, packaging standards, and custom cart or container designs that improve ergonomics and presentation at point-of-use. Establish headcount, labor rates, and efficiency standards to support production and budget planning. Lead the design-in of ergonomics, operator aids, racks, carts, and WIP management systems that enhance safety and efficiency. Deploy discrete event simulation and digital twin modeling to evaluate throughput, optimize resource allocation, and validate production scenarios for both NPI and sustaining lines. Collaborate with cross-functional teams - Manufacturing Engineering, Operations, Facilities, Quality, Safety, and Finance - to implement world-class production systems. Support the start-up and ramp-up of new factories, including scenario simulation, throughput modeling, and layout optimization for Covington and other potential sites. Drive continuous improvement through kaizen events, standard work audits, and lean training across operations.

Requirements

Bachelor's or Master's degree in Industrial Engineering, Manufacturing Systems, or related field (Ph.D. preferred).
10+ years of experience in industrial engineering, with at least 3 years in a leadership capacity.
Deep expertise in lean manufacturing, Six Sigma, and continuous improvement methodologies.
Proven track record developing and implementing standardized processes and factory layouts in a complex, fast-paced manufacturing environment.
Hands-on experience with time studies, motion analysis (MODAPTS), and work measurement tools.
Skilled with discrete event simulation tools and plant layout tools.
Experience defining and managing MPP routings, MES integrations, and SAP cost models.
Strong understanding of ergonomics, material presentation, and human-machine interface design.
Demonstrated success leading teams in data-driven decision making and performance improvement.
Excellent communication and organizational skills with the ability to influence across technical and non-technical functions.
Comfortable managing ambiguity, prioritizing multiple programs, and driving accountability in a high-growth environment.

Nice To Haves

Experience in aerospace or EV industry
Experience with Siemens Plant Simulation
Experience with Siemens Manufacturing Process Planner or EasyPlan
Experience with AutoCAD

Responsibilities

Lead the Industrial Engineering (IE) organization responsible for defining, standardizing, and optimizing systems globally across Archer's engineering, manufacturing, and supply chain.
Build and develop a high-performing team of Industrial Engineers focused on process design, capacity analysis, layout optimization, and lean implementation.
Own the development of Manufacturing System Design (MSD) - ensuring seamless integration of people, machines, materials, and information through all phases: plan, design, validate, and improve.
Drive the standardization of IE methodologies, including: Standardized Work Instructions (SWI), Work Combination Tables (WCT), and Standard Operation Sheets (SOS).
PFEP (Plan for Every Part), containerization, and parts presentation planning in partnership with Logistics.
Value Stream Mapping (VSM), EPEI analysis, OEE calculation, and capacity studies to identify bottlenecks and improvement opportunities.
Oversee plant and warehouse layout design, including space utilization studies, storage systems, and material flow paths that tie directly to CapEx and operational efficiency.
Design warehouse and lineside material flow systems, including kitting strategies, packaging standards, and custom cart or container designs that improve ergonomics and presentation at point-of-use.
Establish headcount, labor rates, and efficiency standards to support production and budget planning.
Lead the design-in of ergonomics, operator aids, racks, carts, and WIP management systems that enhance safety and efficiency.
Deploy discrete event simulation and digital twin modeling to evaluate throughput, optimize resource allocation, and validate production scenarios for both NPI and sustaining lines.
Collaborate with cross-functional teams - Manufacturing Engineering, Operations, Facilities, Quality, Safety, and Finance - to implement world-class production systems.
Support the start-up and ramp-up of new factories, including scenario simulation, throughput modeling, and layout optimization for Covington and other potential sites.
Drive continuous improvement through kaizen events, standard work audits, and lean training across operations.