Lead Manufacturing Engineer

Worker Type

Job Description

The Lead Manufacturing Engineer is responsible for defining launching and improving manufacturing processes for Titan C-UAS electrical and mechanical products with a strong focus on contract manufacturing (CM). This role supports the technical transfer of products to CMs ensures robust production readiness and drives ongoing process improvements using data and structured problem-solving. The Lead Manufacturing Engineer collaborates closely with design engineering supply chain quality and CM partners to achieve reliable cost effective and scalable production.

Key Responsibilities Include:

Contract Manufacturing Technical Support -

• Serve as a primary day to day technical contact for contract manufacturers producing electrical and mechanical assemblies.
• Support NPI and production transfers to CMs by defining build strategy documenting processes and resolving technical issues during initial builds and ramp.
• Review and provide feedback on CM work instructions assembly procedures inspection plans and test procedures to ensure they meet product and quality requirements.
• Monitor CM performance (yield rework scrap cycle time) and support improvement actions in partnership with Supply Chain and Quality.
• Participate in CM audits build readiness reviews and on site troubleshooting as required.

Process Development & Setup (Electrical & Mechanical) -

• Develop maintain and improve manufacturing processes for electrical and mechanical assemblies including PCB-based products harnesses machined and sheet metal parts and system-level integrations.
• Establish and maintain standard times and sequences of operations for current and future production processes both internal and at CMs.
• Generate and update work instructions assembly procedures visual aids and other documentation to control and standardize manufacturing processes.
• Participate in the design and development of manufacturing workflows and equipment layout for efficient safe and ergonomic operations.
• Support Design for Manufacturability/Assembly (DFM/DFA) activities with design engineering and CMs to improve build robustness yield and cost.

Data-Driven Continuous Improvement -

• Analyze production metrics (yield capacity cost process capability) from internal builds and CMs to identify trends and improvement opportunities.
• Help implement Lean Manufacturing and Six Sigma tools to drive reductions in cost lead time and variability.
• Participate in PFMEA and support DFMEA to identify and mitigate manufacturing risks and ensure adequate process controls.
• Support development of manufacturing strategies and capacity models for new and existing products including inputs for capital and tooling needs.

Tooling Fixtures and Make/Buy Support -

• Support cost estimating and requirements definition for new tooling fixtures and test equipment needed to support manufacturing at CMs and internal facilities.
• Contribute to Make/Buy analysis and trade studies in collaboration with cross functional teams for key assemblies and processes.
• Provide guidance on process capabilities and equipment utilization to best align design intent and manufacturing methods.

Production Floor & Hands-On Support-

• Provide hands-on support to internal production and CM builds including troubleshooting integration and assembly issues.
• Participate in root cause analysis and corrective action activities for issues related to materials design tooling process or operator error.

Basic Qualifications (Required Skills & Experience):

• Bachelors degree in Industrial Mechanical Manufacturing Electrical Engineering or related field; or equivalent combination of education training and experience.
• 510 years of experience in Manufacturing Industrial Mechanical Electrical or Test Engineering in aerospace defense automotive or similar high reliability industries.
• Experience supporting or managing contract manufacturers or external suppliers for electrical and/or mechanical assemblies.
• Working knowledge of electro mechanical manufacturing including interpretation of drawings specifications and Bills of Material.
• Familiarity with PCB-based products sheet metal machined parts and basic integration/assembly processes.
• Experience with Lean Manufacturing and Six Sigma principles and tools for process development and control.
• Proficient in Microsoft Office (Word Excel PowerPoint Outlook; Visio/Project a plus).
• Familiarity with statistical analysis tools (e.g. MiniTab) MRP/ERP systems (Oracle preferred) PLM/Change systems (e.g. Agile) and CAD programs (SolidWorks preferred).
• Experience working with ECO/ECN processes.
• Ability and willingness to travel to CM/supplier sites (up to 25% as needed).

Other Qualifications & Desired Competencies:

• Certification in Lean / Six Sigma (Green Belt or higher) preferred.
• Demonstrated problem-solving and analytical skills including root cause analysis techniques (5 Why fishbone 8D participation).
• Strong organization planning and time management skills; able to handle multiple priorities across internal and CM activities.
• Effective verbal and written communication skills; able to collaborate with engineering operations supply chain quality and CM personnel.
• Ability to work within defined requirements and deadlines and to perform independently with moderate oversight.
• Comfortable in a fast paced deadline driven environment where small teams share a broad variety of duties.
• Demonstrated initiative ownership and a continuous improvement mindset.
• Experience working within ISO based or similar quality systems.

Physical Demands:

• Ability to work in an office environment (constant).
• Ability to sit and stand for extended periods; talk hear and use hands and fingers to operate a computer and telephone keyboard (frequent).
• Ability to work in lab and production environments including CM facilities as needed (occasional).

Special Requirements:

• U.S. Citizenship required.
• Occasional domestic and international travel may be required.

Clearance Level

The salary range for this role is:

AeroVironment considers several factors when extending an offer including but not limited to the location the role and associated responsibilities a candidates work experience education/training and key skills.

ITAR Requirement:

This position requires access to information that is subject to compliance with the International Traffic Arms Regulations (ITAR) and/or the Export Administration Regulations (EAR). In order to comply with the requirements of the ITAR and/or the EAR applicants must qualify as a U.S. person under the ITAR and the EAR or a person to be approved for an export license by the governing agency whose technology comes under its jurisdiction. Please understand that any job offer that requires approval of an export license will be conditional on AeroVironments determination that it will be able to obtain an export license in a time frame consistent with AeroVironments business requirements. A U.S. person according to the ITAR definition is a U.S. citizen U.S. lawful permanent resident (green card holder) or protected individual such as a refugee or asylee. See 22 CFR 120.15. Some positions will require current U.S. Citizenship due to contract requirements.

Benefits: AV offers an excellent benefits package including medical dental vision 401K with company matching a 9/80 work schedule and a paid holiday shutdown. For more information about our company benefit offerings please visit: also encourage you to review our company website at to learn more about us.

Principals only need apply. NO agencies please.

About AV:

AV isnt for everyone. We hire the curious the relentless the mission-obsessed. The best of the best.

We dont just build defense technologywe redefine whats possible. As the premier autonomous systems company in the U.S. AV delivers breakthrough capabilities across air land sea space and cyber. From AI-powered drones and loitering munitions to integrated autonomy and space resilience our technologies shape the future of warfare and protect those who serve.

Founded by legendary innovator Dr. Paul MacCready AV has spent over 50 years pushing the boundaries of what unmanned systems can do. Our heritage includes seven platforms in the Smithsonianbut were not building history were building whats next.

If youre ready to build technology that matterswith speed scale and purposetheres no better place to do it than AV.

We are proud to be an EEO/AA Equal Opportunity Employer including disability/veterans. AeroVironment Inc. is an Equal Employment Opportunity (EEO) employer and welcomes all qualified applicants. Qualified applicants will receive fair and impartial consideration without regard to race sex color religion national origin age disability protected veteran status genetic datasexual orientation gender identity or other legally protected status.

ITAR