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Shield AI

Posted 9 months ago

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Staff Engineer, Advanced Manufacturing (R4301)

DallasOn-siteFull-time

AI Summary

Staff Engineer defining manufacturing sequences, standardized work, and repeatable processes for aerospace assemblies; leads production stability, kaizen improvements, and cross-functional quality and tooling collaboration.

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 NPI Manufacturing Engineer leverages 7+ 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

    5SControl PlansDOEExcelFAILeanMESMinitabPFMEAQMSS&OPSPC

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