Sr Manufacturing Process Engineer (UAV/USV)

Ideal Aerosmith•Grand Forks, ND

1d•Onsite

About The Position

Ideal Aerosmith is a leading supplier of precision inertial guidance test systems, flight motion simulators, innovative defense solutions in support of the warfighter, and a premier provider of aerospace test engineering services, ATE system engineering, and quality contract manufacturing services to the aerospace industry. We're experts and we earn that title every day with our customers through innovative engineering, manufacturing, and sustainment of world-class motion and electric test solutions and services. Here, we don’t just solve complex problems - we redefine what’s possible. Every role at Ideal Aerosmith supports a lean culture through continuous improvement - ongoing, incremental enhancements to products, processes, or services aimed at reducing waste and boosting efficiency, customer service, and performance. With a team of skilled problem solvers and a culture that thrives on tackling challenges head-on, we are dedicated to our clients' success. Enjoy competitive benefits, a supportive work environment, and every other Friday off to recharge. We are seeking a Senior Manufacturing Process Engineer to lead the development, optimization, and scaling of system-level integration and production processes supporting our Unmanned Aerial Vehicle (UAV) and Unmanned Surface Vehicle (USV) programs. This role partners closely with Engineering, Quality, Supply Chain, and Program Management to ensure manufacturing execution is disciplined, repeatable, scalable, and production-ready. The ideal candidate will have a strong background in aerospace or complex electromechanical manufacturing environments, including system integration, production flow design, rate-readiness planning, and manufacturing documentation control. This position plays a critical role in transitioning advanced platforms from prototype builds to rate-capable production. The Senior Manufacturing Process Engineer will establish standardized work instructions, MBOM structures, integration sequencing strategies, and production control frameworks designed to sustain long-term program growth within configuration-controlled environments. This position directly supports Department of War (DoW) programs and requires the ability to design and implement manufacturing systems that operate within configuration-controlled, audit-ready, and contract-compliant production environments.

Requirements

Bachelor’s degree in Mechanical, Aerospace, Manufacturing, or related Engineering discipline
7–12+ years of experience in aerospace or complex electromechanical manufacturing environments
Demonstrated experience establishing or significantly expanding manufacturing capability in a new or growing production environment
Demonstrated experience scaling products from prototype to production
Proven experience designing and implementing manufacturing processes
Experience leading RCCA investigations and systemic production improvements
Experience working in regulated or defense manufacturing environments
Must be eligible to obtain and maintain a DoD Secret security clearance.
Must be a U.S. Citizen.
Strong systems-level thinking and manufacturing process design capability
Advanced troubleshooting and analytical problem-solving skills
Ability to lead technical initiatives without formal authority
Strong written documentation discipline
Ability to operate effectively in fast-scaling production environments
Ability to work on-site in a production environment
Ability to stand for extended periods
Ability to lift up to 45 pounds
Ability to work around electromechanical systems and production equipment

Nice To Haves

Experience leading or mentoring junior manufacturing engineers
Experience establishing manufacturing standards across multiple programs
Familiarity with ERP, PLM, and configuration-controlled build environments
Experience supporting defense or government system production

Responsibilities

Lead manufacturing system development for new UAV production facility stand-up, including integration cell design, documentation frameworks, and process governance structures
Design and implement scalable system-level integration processes
Develop standardized production frameworks across programs and product lines
Establish manufacturing flow, line layout, and integration sequencing strategies
Define tooling, fixtures, and process control requirements
Lead MBOM development and manufacturing structure definition
Define production infrastructure requirements including tooling strategy, workspace layout, integration cell architecture, and material flow systems
Lead transition from prototype builds to low-rate and full-rate production
Conduct production readiness reviews and rate capability assessments
Identify systemic bottlenecks and implement structural improvements
Develop capacity planning inputs in coordination with Production Leadership
Drive measurable improvements in yield, throughput, and repeatability
Define and implement integration process controls and verification checkpoints to ensure end-item quality, configuration integrity, and first-pass yield performance at production rate
Establish production-to-test handoff criteria and ensure manufacturing processes support ground test, acceptance testing, and flight readiness requirements
Establish standardized manufacturing change control processes aligned with engineering configuration management
Define and monitor key manufacturing performance metrics including first-pass yield, integration defect rate, rework hours, and rate capability
Serve as escalation point for complex integration and assembly issues
Lead root cause and corrective action (RCCA) efforts
Mentor Manufacturing Team Leads and Production Technicians
Establish best practices for integration quality and process discipline
Drive continuous improvement initiatives across production lines
Ensure alignment between engineering configuration and manufacturing execution
Lead First Article Inspection (FAI) manufacturing support
Ensure documentation integrity, traceability, and audit readiness
Support ISO-9001 and contractual production compliance requirements
Establish standardized manufacturing documentation controls
Provide senior-level Design for Manufacturability (DFM) input to Engineering
Coordinate with Supply Chain on integration constraints and production risk
Support Program Management with production risk identification and mitigation
Participate in IPT leadership discussions related to production execution
Support strategic make/buy and integration planning decisions