Posted 5 months ago

Senior Staff Engineer, Advanced Manufacturing (R4359)

DallasOn-siteFull-time

AI Summary

Senior Staff NPI Manufacturing Engineer responsible for establishing manufacturing sequences, work instructions, and processes for aerospace assemblies to accelerate rate and improve quality.

About this role

Founded in 2015, Shield AI is a venture-backed deep-tech company with the mission of protecting service members and civilians with intelligent systems. Its products include the V-BAT and X-BAT aircraft, Hivemind Enterprise, and the Hivemind Vision product lines. With offices and facilities across the U.S., Europe, the Middle East, and the Asia-Pacific, Shield AI’s technology actively supports operations worldwide. For more information, visit www.shield.ai. Follow Shield AI on LinkedIn, X, Instagram, and YouTube.

Job Description:

The Senior Staff NPI Manufacturing Engineer leverages 10+ years of experience establishing manufacturing sequences, standardized work, ergonomic workstations, and MES-driven instructions for aerospace assemblies. This role drives production stability during early builds and rate acceleration by developing repeatable processes, eliminating waste, and enhancing quality.

What you'll do:

Define the Bill of Process and manufacturing sequence for assigned subassemblies or cells.

Map MBOM to operations, tooling needs, and process controls.

Build ergonomic workstations (height/reach zones, shadow boards, calibrated torque tools, ESD controls, POU materials).

Create visual, operator-ready Work Instructions with torque specs, PPE, inspection points, and MES revision control.

Conduct time studies, compute takt/CT, identify bottlenecks, and lead kaizen improvements.

Establish standardized work, visual controls, job aids, and layered audit systems; iterate with operators.

Capture shop-floor lessons learned defects, build issues, tooling feedback and drive root cause and corrective action.

Partner with Quality on in-process checks, error-proofing, and FAI readiness.

Implement ECOs, validate process updates, and maintain work instructions accordingly.

Tools & Skills: MES/QMS systems, torque analyzers, Minitab/Excel (SPC, capability, DOE), lean/5S, PFMEA, ergonomic assessment tools, Control Plans, Standard Operating Procedures.

Required qualifications:

7+ years of experience in manufacturing engineering, production systems, process development, or assembly engineering.

Bachelor’s degree in Mechanical, Industrial, Mechatronics, or related STEM field.

Experience in prototype manufacturing in a startup or rapid-growth environment.

Strong understanding of manufacturing processes, including machining, composites, avionics and/or assembly.

Demonstrated ability to work in a fast-paced, high-pressure environment and adapt to changing priorities.

Preferred qualifications:

Knowledge of quality standards, such as AS9100 or ISO 9001.

Proficiency in CAD software

Familiarity with advanced manufacturing technologies, such as additive manufacturing or automation systems.

Hands-on experience with manufacturing equipment and tooling design.

Strong project management skills, including experience managing multiple priorities and deadlines

Skills

5SCADControl PlansCTDOEECOsErgonomic Assessment ToolsExcelFAI ReadinessKaizenLeanMESMinitabPFMEAQMSQuality Standards (AS9100/ISO 9001)SOPsSPCTakt TimeTooling DesignTorque AnalyzersVisual Work Instructions

Senior Staff Engineer, Advanced Manufacturing (R4359)

About this role

What you'll do:

Required qualifications:

Preferred qualifications:

Skills

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