Senior Manufacturing Engineer Jobs in Sycamore, IL

The Senior Manufacturing Engineer shall be highly skilled and experienced to support and lead efforts related to operational excellence within a rapidly growing aviation manufacturing and FAA Part-145 repair business backed by a successful Public Company. Initial focus will be on facility relocation and process stabilization, with longer-term emphasis on continuous improvement. This role combines hands-on engineering, Lean process design, equipment maintenance and safety strategy, and technical troubleshooting to ensure a smooth transition and long-term performance of production, repair, and testing systems.  The “hands on” philosophy will include learning how to fabricate and repair the various products to better aid in implementing improvements.  This role will also include responsibilities as the Safety Coordinator.  The successful candidate must have an excellent technical aptitude, be analytical and detail oriented, and be able to thrive in a fast-paced environment with a diverse product line.

Who We Are

DAC Engineered Products is a prominent aerospace company recognized for our dedication to maintaining and repairing aircraft to the highest standards of safety and quality. With an extensive history in knowledge and sales, DAC-EP Engineered Products brings forth a legacy of excellence, poised to shape the future of aerospace engineering.

BENEFITS:
This is a full-time, hourly position with competitive pay and opportunities for advancement within the company. We offer a comprehensive benefits package including medical, dental, and vision insurance, 401(k) matching, paid time off, and employee discounts.

Salary Range: $95,000 to $130,000/year
Responsibilities:

• Design support at all stages of the design process from vetting to proposal, through design, manufacturing, and qualification testing until completion and product introduction.
• Lead and coordinate engineering activities for a full-site relocation, including logistics planning and the development of shop floor layouts using Lean principles to improve workflow, reduce waste, and optimize space utilization.
• Develop and maintain Manufacturing Orders (MO), Bill of Operations (BOO), and Bill of Materials (BOM) within electronic ERP system.
• Apply Lean manufacturing tools (5S, Kaizen, VSM, SMED, standardized work, visual controls) to improve efficiency and reduce variation.
• Write, review, train on, and support production with respect to SOP/SWI documents, product work instructions, and inspection processes.
• Collaborate with operations team to maintain or improve, as needed, KPIs such as TAT, FPY, and scrap/rework.
• Collaborate with QA team on root-cause analysis and corrective action activities for quality, performance, and safety issues.
• Collaborate with operations team to create or refine preventive and predictive maintenance programs for production equipment.
• Troubleshoot and assess risks with the MRB team regarding complex equipment, tooling, and process problems to minimize and plan for downtime and maintain product quality and safety compliance.

Requirements:

• Bachelor’s degree in Manufacturing, Mechanical, Industrial Engineering, or related field required (advanced degree preferred).

• 7+ years of manufacturing engineering experience, ideally in the aviation/aerospace industry required.
• Demonstrated experience leading or supporting a facility move, production line relocation, or major layout transformation.
• Strong hands-on experience with equipment maintenance, troubleshooting, and reliability engineering.
• Proven track record implementing Lean manufacturing tools and driving continuous improvement.
• Knowledge of aviation quality and regulatory standards (AS9100, NADCAP, FAA).
• Solid understanding of workplace safety regulations and procedures - OSHA requirements, safety engineering principles, and compliant equipment/system design.
• Strong CAD, ERP/MRP, and data analysis skills.
• Excellent project management, communication, and cross-functional leadership abilities.
• MUST be mechanically inclined with an eye for details.
• Proficiency with Microsoft Office products.
• Six Sigma Green/Black Belt or formal Lean certification preferred.
• Experience with CMMS systems and equipment reliability programs preferred.
• Background in CNC machining, composites, welding, aerospace assembly, or complex test systems preferred.
• Experience with APQP, PPAP, 8D, and structured problem-solving methodologies preferred.
• Training or certification in safety (OSHA 30, NEBOSH, CSP, or equivalent safety engineering coursework) preferred.

EEOC Statement:
DAC Engineered Products LLC is an equal opportunity employer and is committed to creating a diverse and inclusive workplace. We do not discriminate on the basis of race, color, religion, sex, sexual orientation, gender identity, national origin, age, disability, genetic information, veteran status, or any other legally protected status.