Lead Manufacturing Engineer - DFMA, Avionics

The Role

Great hardware balances performance, manufacturability and serviceability. Mach is building unmanned defense systems at a rate the traditional defense industrial base was never designed for. That takes designs that are built to be built: fast, right the first time, at the lowest cost, and easy to maintain in the field.

This is a hands-on technical leadership role with direct reports. As Lead Manufacturing Engineer, Avionics, you'll be Mach's go-to expert on designing electronics, harnesses and avionics boxes so they can be built, tested, installed and maintained quickly and without errors. You'll write Mach's Avionics DFMA guide. You'll push the field forward through research and development (R&D) on new materials, hardware and processes.

Key Responsibilities

Own the Avionics DFMA guide

• Write, publish and maintain Mach's Avionics DFMA guide. It should cover:
  • design rules, with the reasoning and test data behind them
  • preferred components, connectors, wire and processes
  • standard features and tolerances
  • worked examples and review checklists
• Write design-for-manufacturing, assembly and test rules (DFM, DFA, DFT) for PCBAs, wire harnesses, connectors and avionics enclosures (box build).
• Set connector retention and mate-assurance standards:
  • two-stage connector position assurance (CPA) clips that ship pre-staged
  • terminal position assurance (TPA) locks to confirm every terminal is fully seated
  • audible, tactile and visual full-mate indicators, such as color-coded CPAs
  • limits on mating and CPA engagement force (for example, per SAE/USCAR-25)
• Define how each connection is checked at the station: push-pull-push checks, CPA position checks by vision, and electrical continuity or mate-detect tests.
• Define the DFMA sign-off criteria for design gates and hold programs to them.
• Set and track DFMA metrics for each program, such as part count, unique connector count, assembly and test time, first-pass yield and cost.
• Keep the guide current with test results, production lessons and supplier input. Train design and manufacturing engineers to apply it.

Shape designs early

• Review vehicle and electrical architecture at concept, before designs lock: box placement, harness layout and connector strategy.
• Lead static and kinematic assembly studies (virtual builds) before hardware exists. Check harness routing, install paths, and hand and tool access to mate each connector and seat its CPA. Set harness routing, retention and installation rules.
• Drive content reduction (fewer connectors, wires and boards), simpler assembly, build-in-quality and ergonomic access. Push for features that suit automation.
• Define avionics poka-yoke standards, for example:
  • connector keying and clocking
  • a unique connector per interface
  • two-stage CPA clips and TPA locks
  • blind-mate or tool-less installation
• Lead value engineering on released designs: challenge assumptions and take out cost.

Enable trade studies and make vs. buy

• Build should-cost, cycle-time and rate models that show how design choices affect cost, capital investment, schedule and quality.
• Write the manufacturing requirements in RFQ packages for contract manufacturers and help evaluate supplier quotes.

Lead R&D

• Lead R&D on automated harness fabrication, flex and rigid-flex circuits that replace harnesses, simpler interconnects, and faster-curing potting and coatings.
• Develop connector and CPA designs that confirm a full mate automatically, through vision or electrical mate detection.
• Plan and run designed experiments (DOE). Build test articles, test to failure, analyze results with sound statistics, and publish findings.
• Co-develop new components, processes and equipment with suppliers, contract manufacturers, equipment makers, universities and national labs.
• Lead manufacturing trials during prototype / validation builds to prove new processes.

Support production and suppliers

• Assess contract manufacturers, harness shops and connector suppliers on site, and push them toward best practices and lower investment.
• Work with connector suppliers on CPA and TPA design and qualification.
• Bring avionics expertise to design and process FMEAs (DFMEAs and PFMEAs). Maintain a library of known failure modes and proven controls.
• Lead root cause analysis on escapes and repeat defects, e.g. partially mated connectors, solder defects, miswires / connector damage. Feed fixes into the guide.
• Mentor engineers and help build Mach's DFMA function.

Required Qualifications 

• BS in Electrical, Mechanical, Manufacturing or Industrial Engineering, or equivalent. 
• 8+ years in avionics, PCBA or harness manufacturing or design engineering. This includes taking hardware from design into production at rate in aerospace, defense, automotive or consumer electronics.
• Working knowledge of IPC-A-610, J-STD-001 and IPC/WHMA-A-620.
• Experience with SMT processes, box build and electrical test.
• A track record of writing design standards, guides, process specs.
• Strong manufacturing and industrial engineering fundamentals: cycle time analysis, OEE, process capability (Cp/Cpk), gauge R&R, DOE, error proofing, ergonomics and ROI.
• Working knowledge of GD&T (ASME Y14.5) and tolerance stack-ups.
• Skilled in 3D CAD (NX, CATIA, SolidWorks or similar) and comfortable in ECAD tools.

Preferred Qualifications

• MS in Electrical Engineering or a related field.
• Knowledge of automotive connector standards (for example, SAE/USCAR-2 and USCAR-25) and MIL-spec connectors (for example, MIL-DTL-38999).
• Experience with automotive high-volume harness and connector systems.
• Experience ruggedizing defense electronics (MIL-STD-810, shock and vibration).
• IPC CIS or CIT certification
• Experience with both high-rate automotive or consumer electronics production
• Formal DFMA methods (for example, Boothroyd Dewhurst), should-cost modeling, and value engineering programs with measured savings.
• Experience leading DFMEAs and PFMEAs.
• Patents, publications, or processes you developed and put into production.
• Experience in an AS9100 or defense production environment.
• Lean or Six Sigma certification.

Additional Requirements

• Available to work extended hours and weekends as needed

ITAR Requirements

To conform to U.S. Government export regulations, applicant must be a (i) U.S. citizen or national, (ii) U.S. lawful, permanent resident (aka green card holder), (iii) Refugee under 8 U.S.C. § 1157, or (iv) Asylee under 8 U.S.C. § 1158, or be eligible to obtain the required authorizations from the U.S. Department of State. Learn more about the ITAR here.  

Senior Engineer 140000 - 180000 USD