Lean Manufacturing Jobs in Virginia (NOW HIRING)

Job Title: Manufacturing Engineer
Industry: Aerospace & Defense Manufacturing
On-site Location: Stafford, VA
Relocation Provided: Yes
Salary Range: $90,000 - $125,000 (More if strong in Electrical Engineering)

Job Overview:

The Manufacturing Engineer will support full-scale production, integration, and testing of high-tech unmanned aerial systems, including tactical drones and loitering munitions. This role requires a strong combination of electrical/electronic engineering and mechanical engineering expertise, with hands-on experience in assembling complex electromechanical systems.

You will interface daily with engineers, production technicians, quality, supply chain, and program leadership to build repeatable processes, optimize assembly workflows, resolve build issues, and ensure that all aircraft, avionics, wiring harnesses, and mechanical subsystems integrate seamlessly.

This role is ideal for someone who thrives in a fast-moving defense manufacturing environment where requirements evolve quickly, engineering data may be incomplete, and the team relies heavily on practical engineering judgment, root-cause analysis, and cross-functional collaboration.

Minimum Requirements:

• 5+ years of experience in manufacturing or production engineering within aerospace, defense, unmanned systems, missiles, electromechanical devices, or similar high-reliability products.
• A bachelor's degree in Mechanical, Electrical, Manufacturing Engineering, or a related field is required
• Proficiency in modifying and updating engineering drawings, CAD
• Must be a U.S. citizen with the ability to obtain Clearance after being hired.
• Demonstrated ability to write and maintain standard operating procedures (SOPs).
• Strong background in production operations and continuous improvement methodologies.
• Experience with various manufacturing processes like CNC, Injection Molding, Sheet Metal, 3D printing, and Composites.
• Experience with mechanical assembly, precision hardware, GD&T, torque specifications, and vibration/shock considerations & testing setups.
• Background in lean manufacturing, six sigma, line balancing, or continuous improvement.
• Experience with AS9100, ITAR, and defense production documentation requirements.
• Working knowledge of wiring harness assembly, PCB integration, and basic electronics troubleshooting.
• Hands-on experience with assembly, testing, and troubleshooting of electro-mechanical systems.
• Strong understanding of NPI processes and design-for-manufacturing (DFM) principles.
• Proficiency in interpreting GD&T, PCBA schematics, BOMs, and technical specifications.
• Ability to work onsite daily in a hands-on production environment.

Preferred Requirements:

• Experience in manufacturing UAVs, loitering munitions, guided systems, avionics packages, or other tactical defense systems.
• Familiarity with flight control systems, IMUs, servos, telemetry radios, and embedded electronics.
• Experience supporting FAI, MRB, FRACAS, configuration management, and DoD reporting requirements.
• Python or scripting knowledge for testing automation is a plus.

Responsibilities:

Production & Integration Engineering

• Lead hands-on integration of electrical, electronic, and mechanical subsystems, including avionics, wiring harnesses, sensors, actuators, power systems, propulsion, and structural airframe components.
• Troubleshoot and resolve build issues on the production floor, providing real-time support to technicians and ensuring efficient, repeatable, and compliant assembly processes.
• Perform functional testing, continuity checks, firmware loading, calibration, and validation of electromechanical subsystems.

NPI (New Product Introduction) Support

• Partner with R&D, design engineering, and supply chain teams to transition prototypes into full-rate production.
• Develop and validate manufacturing processes for new products, including creation of tooling, fixtures, jigs, and assembly and test methods.
• Participate in engineering design reviews to ensure manufacturability, reliability, and cost-effectiveness.

Technical Data Package (TDP) & Documentation

• Interpret and clarify engineering drawings, PCBA schematics, wiring diagrams, BOMs, specifications, and configuration requirements for both internal teams and external suppliers.
• Serve as the primary technical liaison for TDP-related questions, ensuring all documentation is accurate, complete, and production-ready.
• Create and maintain Assembly Work Instructions (AWIs), SOPs, quality checks, and production routers.

Process Engineering & Continuous Improvement

• Define, optimize, and standardize assembly and test processes for electro-mechanical UAV systems.
• Lead root-cause analysis and corrective actions for production issues using 5 Whys, DMAIC, fishbone, FRACAS, or similar methodologies.
• Implement lean manufacturing principles, takt time and line balancing improvements, waste reduction initiatives, and production workflow optimization.

Quality, Compliance & Manufacturing Controls

• Ensure compliance with AS9100, ITAR, configuration management, and controlled defense manufacturing requirements.
• Support FAI, MRB, FRACAS, quality inspections, and component qualification activities.
• Drive build consistency, reliability, and repeatability across production lines.

Supplier & Cross-Functional Collaboration

• Work closely with supply chain, procurement, supplier development, and quality engineering to ensure alignment on technical requirements, manufacturability, and component readiness.
• Support supplier onboarding, provide technical clarification, and assist with training related to processes, TDP interpretation, and assembly expectations.
• Collaborate with R&D and design engineering to influence design-for-manufacturability (DFM) and resolve technical discrepancies efficiently.