Manufacturing Engineer

Company Overview
Performance Drone Works (PDW) builds technologies for the warfighter, by the warfighter. Born out of the Drone Racing League, our roots are competitive, our mindset is tactical, and our mission is clear: deliver purpose-built unmanned systems to those who serve. We are not here to sell vapor; we build and ship real capabilities for real missions.

Now, we're entering a new phase of growth and are looking for a Manufacturing Engineer to drive manufacturability, production readiness, and scalable factory design across multiple sUAS platforms. This role partners with Design Engineering, Quality, Supply Chain, and Operations to lead DFM/DFMA, NPI industrialization, tooling and fixturing, built-in quality, capacity modeling, automation readiness for high-volume production, and factory/line layout optimization to improve throughput, cost, quality, and safety.

What You'll Do

* Lead DFM/DFMA reviews from concept through release; deliver clear, prioritized design change recommendations that improve assembly, test, serviceability, and cost.

* Translate design intent into scalable manufacturing processes: define process flow diagrams, value stream maps, routings, and work content for assembly and test.

* Establish and maintain labor standards through time studies (stopwatch, MOST/MTM as applicable); create standard work and staffing models aligned to takt.

* Develop capacity models for critical work centers and resources (labor, equipment, test stations); identify bottlenecks and drive mitigation plans.

* Own factory/line/cell layout development and optimization: material flow, kitting, point of use storage, WIP control, and ergonomic/safety considerations.

* Identify, evaluate, and industrialize automation opportunities for high-volume assembly and test (e.g., automated screwdriving, dispensing, vision inspection, inline functional test, and serialization/traceability), partnering with Manufacturing Systems and Automation Engineering, and equipment vendors.

* Support specification, layout, and commissioning of automated workcells and production lines: cycle time studies, line balancing, OEE/downtime analysis, safety integration, and ramp stabilization to steady-state performance.

* Define, specify, and validate production tooling, fixturing, and gaging (assembly jigs, test fixtures, torque tooling, and poka-yoke devices) to enable safe, repeatable, and efficient builds.

* Partner with NPI to plan and execute prototype, pilot, and ramp builds: line readiness checklists, tooling/fixturing/gage needs, training plans, and build learning capture.

* Drive line balancing and continuous improvement initiatives (5S, kaizen, Kanban, SMED, poka-yoke) to reduce waste and increase throughput.

* Embed built-in quality into process design: in-station verification, error proofing, standardized work, and capability targets (SPC/process capability as applicable) to improve first pass yield and prevent escapes.

* Collaborate with Manufacturing, Quality and Core Engineering on PFMEAs, control plans, and inspection/test strategies, incorporate capability targets and feedback loops.

* Support cost and investment decisions by quantifying labor, equipment, and space requirements; contribute to make/buy analyses and capital justifications.

Requirements

• B.S. in Industrial Engineering, Manufacturing Engineering, Mechanical Engineering, or related discipline.
• 7-10 years of industrial engineering experience in a manufacturing environment; aerospace/defense and high-mix electromechanical assembly preferred.
• Demonstrated success leading DFM/DFMA and cross-functional design-to-manufacturing trade studies.
• Strong NPI/industrialization experience (prototype/pilot/ramp) including line readiness, documentation, and ramp planning.
• Experience supporting high-volume, high-throughput manufacturing environments, including designing and scaling automated or semi-automated assembly and test lines.
• Demonstrated experience defining automation equipment requirements and acceptance criteria (URS), supporting capital justifications, and participating in FAT/SAT, process validation, and production ramp to rate.
• Working familiarity with automation technologies and metrics (robotics/cobots, vision systems, automated torque/dispense, conveyors, PLC/HMI concepts, OEE and downtime analysis).
• Hands-on experience defining requirements for manufacturing tooling, fixtures, and gages; coordinating design/fabrication, acceptance testing, and release into production.
• Working knowledge of built-in quality methods (quality at the source, poka-yoke, control plans, PFMEA, gage R&R, and in-process checks) and partnering with Quality to drive capability and reduce escapes.
• Proven capability in capacity planning, line balancing, labor standards, and time studies; advanced Excel/data analysis skills required (Minitab/Power BI a plus).
• Proficiency with layout and visualization tools (AutoCAD, SolidWorks, Visio, or equivalent) and applying ergonomic and safety principles.
• Familiarity with ERP/MES master data and manufacturing documentation (BOMs, routings, work centers, revisions); Lean/Six Sigma experience and strong communication skills.

Physical Requirements

The physical demands described here are representative of those that must be met to successfully perform the essential functions of the job. Ability to sit, stand, bend, reach, climb, and move about regularly throughout the day and lift / carry up to 25 pounds. Must have manual dexterity to operate standard office equipment.

Work Environment

This position typically operates in a standard office setting and manufacturing environment. This role requires use of standard office equipment and may involve exposure to equipment, tools, machinery, hazardous chemicals, or materials relevant to the role. This position may have exposure to outdoor weather conditions, noise, and non-climate-controlled environments. May require the use of personal protective equipment (PPE) depending on the environment. This is a fast-paced work environment and requires cross departmental collaboration with independent and team-based responsibilities. Standard works hours for this position 7:00 a.m. to 3:30 p.m. with occasional overtime as operational needs demand.

Benefits

PDW values our team, and we offer a compensation package reflective of your experience and capabilities. Benefits include:

* Comprehensive BCBS medical, dental, and vision coverage; 80% sponsored by the company.

* Safe Harbor 401(K) with company match.

* Paid Parental Leave.

* A work environment that encourages teamwork and innovation.

* On-site gym at our Huntsville, AL location.

* Employer provided life insurance.

* Robust Employee Assistant Program (EAP).

* Competitive salary, generous paid time off (PTO), and flexible leave options.

EEO Statement

PDW is an equal opportunity employer that upholds all federal and state non-discrimination laws. We ensure a fair and unbiased evaluation for employment for all qualified candidates regardless of race, color, religion, age, sex, sexual orientation, gender identity, national origin, marital status, medical condition, disability, genetic information, veteran status, or any other characteristic protected by law.