Manufacturing Engineer

Job Title: Forensic Manufacturing Engineer

Job Description

The Forensic Manufacturing Engineer plays a key role in building, testing, qualifying, and producing next-generation spacecraft within a low-rate manufacturing and new product introduction environment. This role bridges production, development, tooling, supply chain, and quality teams, leading production on the assembly line while driving continuous improvement. The engineer investigates defective or failed production modules, performs detailed root cause analysis, and develops robust repair and rework processes to improve yield toward 100%. The position requires strong analytical and manufacturing engineering skills, a deep understanding of lean practices, and expertise in optical system performance and metrology.

Responsibilities

• Develop and optimize production processes and technical data, including defining, testing, validating, documenting, and deploying new rework procedures, work order routings, bills of material, and test report structures.
• Lead root cause analysis of failed or defective production materials using structured techniques such as Fishbone, Fault Tree, and DMAIC, ensuring thorough investigation and clear documentation.
• Create and approve detailed teardown and investigation plans for defective modules, and execute special test and teardown activities directly when required.
• Document observations, data, and conclusions from forensic investigations, clearly identifying the root cause of defects and their impact on production yield and product performance.
• Develop corrective action plans and process improvements to prevent recurrence of defects and drive production yield toward 100%.
• Build repeatable repair structures for common module defects by creating comprehensive work instructions, bills of material, and routings for repair shop orders.
• Collaborate closely with design engineering to deliver technical solutions for recurring defect modes and to influence design for manufacturability and serviceability.
• Support low-rate manufacturing and new product introduction by validating new processes, qualifying equipment, and ensuring smooth transition from development to full production.
• Apply lean manufacturing principles and continuous improvement methodologies to reduce waste, improve cycle time, and enhance overall manufacturing efficiency.
• Utilize statistical analysis tools to evaluate process capability, monitor performance, and support data-driven decision making.
• Work with technician teams on the production floor to guide special testing, teardown activities, and implementation of new rework and repair procedures.
• Participate in and sometimes lead root cause review meetings, daily stand-ups, and cross-functional discussions to communicate findings, status, and improvement plans.

Essential Skills

• Proven experience in manufacturing engineering within a low-rate manufacturing environment.
• Demonstrated familiarity with new product introduction processes and challenges.
• Strong knowledge of lean manufacturing practices and principles.
• Hands-on experience with root cause analysis techniques such as Fishbone diagrams, Fault Tree Analysis, and DMAIC.
• Experience with optical system performance and optical metrology, including evaluating and troubleshooting optical components and assemblies.
• Solid analytical skills with the ability to interpret complex data and translate findings into actionable process improvements.
• Mechanical aptitude and understanding of manufacturing processes for complex mechanical and electro-mechanical systems.
• Ability to develop and document production processes, work instructions, bills of material, routings, and test procedures.
• Strong communication skills for documenting investigations, presenting findings, and collaborating with cross-functional teams.

Additional Skills & Qualifications

• Experience with SAP or similar enterprise resource planning (ERP) software.
• Experience with NX Unigraphics or similar computer-aided design (CAD) software such as Siemens NX.
• Experience in aerospace manufacturing and/or optical manufacturing environments.
• Experience working with fiber optic systems and related components.
• Familiarity with continuous improvement methodologies such as Six Sigma.
• Experience with statistical analysis tools, such as Minitab, for process and quality analysis.
• Exposure to medical device, aerospace, or other highly regulated manufacturing industries.
• Understanding of electrical and electro-mechanical systems in a manufacturing context.
• Programming or scripting experience in Python for data analysis or process automation is a plus.

Work Environment

This role supports production for a satellite program focused on next-generation spacecraft. The engineer splits time between the production floor, individual analytical work, and cross-functional meetings. Approximately 40% of the time is spent on the production floor working directly with technician teams to execute special tests, teardowns, and investigations on defective materials. Another 40% is dedicated to self-directed work away from the production floor, including developing test and teardown plans, documenting forensic investigation results, and creating standard rework and repair plans. The remaining 20% is spent in meetings such as root cause review sessions and daily stand-ups with production, quality, design, and other stakeholders. The environment emphasizes collaboration, continuous improvement, and the use of advanced technologies and tools, including CAD systems like NX Unigraphics, ERP systems such as SAP, statistical analysis software like Minitab, and optical metrology equipment. The role operates in a high-tech manufacturing setting where safety, precision, and documentation are critical, and where work attire typically aligns with standard production and engineering floor requirements.

Job Type & Location

This is a Contract position based out of Redmond, WA.

Pay and Benefits

The pay range for this position is $63.00 - $78.00/hr.

Eligibility requirements apply to some benefits and may depend on your job classification and length of employment. Benefits are subject to change and may be subject to specific elections, plan, or program terms. If eligible, the benefits available for this temporary role may include the following:

• Medical, dental & vision
• Critical Illness, Accident, and Hospital
• 401(k) Retirement Plan - Pre-tax and Roth post-tax contributions available
• Life Insurance (Voluntary Life & AD&D for the employee and dependents)
• Short and long-term disability
• Health Spending Account (HSA)
• Transportation benefits
• Employee Assistance Program
• Time Off/Leave (PTO, Vacation or Sick Leave)

Workplace Type

This is a fully onsite position in Redmond,WA.

Application Deadline

This position is anticipated to close on Apr 30, 2026.

Diversity, Equity & Inclusion

At Actalent, diversity and inclusion are a bridge towards the equity and success of our people. DE&I is embedded into our culture through:

• Hiring diverse talent
• Maintaining an inclusive environment through persistent self-reflection
• Building a culture of care, engagement, and recognition with clear outcomes
• Ensuring growth opportunities for our people

Actalent is an equal opportunity employer.

About Actalent

Actalent is a global leader in engineering and sciences services. For more than 40 years, we've helped visionary companies advance their goals. Headquartered in the United States, our teams span 150 offices across North America, EMEA, and APAC-with four delivery centers in India led by 1,000+ extraordinary employees who connect their passion with purpose every day.

Our Bangalore, Hyderabad, Pune, and Chennai delivery centers are hubs of engineering expertise, with core capabilities in mechanical and electrical engineering, systems and software, and manufacturing engineering. Our teams deliver work across multiple industries including transportation, consumer and industrial products, and life sciences. We serve more than 4,500 clients, including many Fortune 500 brands. Learn more about how we can work together at actalentservices.com.