Lead Manufacturing Engineer - Vehicle Assembly

The Role

Mach Industries is seeking a Lead Manufacturing Engineer to own the Vehicle Assembly system and production launch for our autonomous defense vehicles. You will deliver the factory designs, stations, tooling, conveyance, and automation needed to go from late-stage prototype builds to full-rate production at Mach's Forge factories, at world-class first-pass yield and production rates.

As a technical lead for vehicle assembly, you'll work closely with Build Engineering, Design Engineering, Manufacturing Operations, Quality, Automation Engineering, Supply Chain, Material Flow, and outside equipment vendors. This is a hands-on technical role with direct reports. You'll shape product designs early, lead builds and production ramps, and mentor a growing team of manufacturing engineers. This role suits an engineer who takes full ownership, solves problems from first principles, and moves quickly without compromising safety or quality.

Key Responsibilities

Launch Ownership and Cross-Functional Readiness

• Serve as an extreme owner of the production launch, from late-stage prototype builds through full-rate production. Own the integrated launch schedule, the readiness criteria for each build phase, and the go/no-go recommendation for each build.
• Run regular launch-readiness reviews using a shared schedule and risk register that covers every team. Make sure each open item has an owner, due date, and recovery plan.
• Find risks to the ramp early, such as late design changes, part shortages, or equipment delays. Put mitigation or containment in place before they affect production, using options such as interim tooling, manual processes, or changes to build sequence.
• Give leadership clear, data-based updates on launch status. Escalate unresolved risks with their impact, the options, and a recommendation.
• Own the launch outcome. Make sure the line reaches its rate, quality, and cost targets on schedule, and lead the recovery when it falls short.

Design for Assembly and Virtual Builds

• Lead design for manufacturing and assembly (DFM/A) reviews at the part, assembly, and system level. Drive part-count reduction, simpler assembly, error-proofing (poka-yoke), built-in quality, and lower cost into vehicle designs.
• Run virtual builds with cross-functional teams to check assembly sequence, hand and tool clearance, GD&T, tolerance stack-ups, and part presentation. Support these reviews with static and kinematic assembly simulations.

Assembly System and Equipment

• Define the Vehicle Assembly system, including sequence, station content, line balance, cycle time, and headcount and equipment capacity. Record in a linked manufacturing bill of materials (MBoM), bill of process (BoP), and bill of equipment (BoE).
• Lead make-vs-buy studies with Supply Chain to secure suppliers that can deliver at rate and keep parts arriving on time.
• Estimate cycle times with predetermined motion time systems (MODAPTS, MOST, or MTM), and design stations that meet NIOSH ergonomic guidelines.
• Develop Vehicle Assembly line layouts with Factory Design, Facilities, and EHS, making the best use of floor space, material flow, and safety, and leaving room for future growth.
• Build capital and operating cost estimates and return-on-investment cases for assembly equipment, and provide process input to requests for quote (RFQs). Take part in vendor design reviews, factory acceptance testing (FAT), and site acceptance testing (SAT) to confirm equipment meets process requirements before production handoff.

Build Execution, Ramp, and Production

• Plan and lead prototype builds and manufacturing trials across Mach’s Huntington Beach and Texas mass-production factories. Design and deliver prototype tooling, and apply lessons learned to the production line design.
• Validate processes and equipment through capability studies (Cp/Cpk), gage repeatability and reproducibility (GR&R), error-proofing checks, and acceptance criteria.
• Release controlled work instructions and quality gates in the manufacturing execution system (MES). Lead the line through ramp to full rate and quality. Provide daily floor support, track first-pass yield, OEE, and cycle time, and remove constraints quickly.

Technical Leadership

• Set technical direction and engineering standards for Vehicle Assembly, and review other engineers' work for quality and consistency.
• Mentor manufacturing engineers, share knowledge across teams, and help hire as the team grows.

Required Qualifications 

• Bachelor's degree in Mechanical, Manufacturing, Industrial and Systems, Aerospace, or Electrical Engineering, or equivalent experience.
• 7+ years of manufacturing engineering experience, including leading complex assembly lines from concept through full-rate production.
• Experience running integrated launch schedules, build-phase readiness reviews, and risk registers from start to finish.
• Hands-on experience specifying, installing, and commissioning assembly equipment, conveyance, tooling, and fixtures, including vendor FAT and SAT.
• Strong knowledge of line design, line balancing, cycle-time analysis, capacity planning, OEE, ergonomics, and error-proofing.
• Proven use of first-principles DFM/A on complex products.
• Experience with PFMEA, control plans, SPC,, and structured problem-solving.
• Proficiency in 3D CAD (Siemens NX, CATIA, or SolidWorks) and AutoCAD factory layouts.
• Proven ability to lead technical projects, mentor engineers, and make sound decisions with incomplete information in a fast-moving environment.
• Exceptional written and verbal communication skills, including presenting risks and recommendations to leadership.

Preferred Qualifications

• Experience in high-rate automotive Vehicle Assembly, aerospace, or defense manufacturing.
• Experience with structured launch frameworks such as APQP or AS9145.
• Experience with manufacturing process planning tools (such as Heliux, DELMIA, or EasyPlan) and MES platforms.
• Working knowledge of PMTS methods and NIOSH ergonomic standards.
• Lean Six Sigma certification 
• Experience launching a new factory or building up a startup's manufacturing operations.
• Experience working in an ITAR-controlled environment.

Additional Requirements

Senior Engineer 140000 - 180000 USD