Staff Forward Deployed Engineer

Staff Foward Deployed Manufacturing Engineer

Summary

The Staff Foward Deployed Manufacturing Engineer leads the deployment, ramp-up, and scaling of advanced manufacturing systems across multiple Deterrence Defense production facilities. This role owns critical manufacturing processes and equipment strategy at the program level, directing commissioning activities and driving cross-site standardization to ensure systems operate safely, efficiently, and reliably. The engineer serves as a technical leader for cross-functional engineering and operations teams — mentoring junior engineers and guiding project teams — to solve complex electromechanical and process challenges in fast-paced, high-throughput production environments.

Key Responsibilities

• Lead development, installation, and ramp-up of advanced manufacturing equipment and automated systems across multiple sites or programs.
• Own performance, reliability, and safety of assigned production equipment and serve as the escalation point for complex technical issues.
• Direct root-cause analysis across mechanical, electrical, controls, and process domains, and guide others through structured problem-solving.
• Drive equipment and process performance improvements through data-driven experimentation and continuous improvement, setting standards adopted across sites.
• Mentor and provide technical guidance to junior and mid-level manufacturing engineers; may lead or coordinate cross-functional project teams.
• Develop specifications, work instructions, operating procedures, and maintenance documentation, and review/approve documentation produced by others.
• Partner with internal stakeholders, program leadership, and suppliers to define requirements, lead equipment readiness reviews, and validate equipment.
• Support process controls, PLC/HMI interactions, automation troubleshooting, and system bring-up.
• Ensure equipment meets all ergonomic, safety, and regulatory standards across all facilities it's deployed to.
• Identify critical spare parts and lead preventive and predictive maintenance strategy across multiple lines or sites.

Qualifications

• Bachelor's degree in Mechanical, Electrical, Chemical, or related engineering field.
• 7+ years of experience in high-volume or high-precision manufacturing environments, including experience supporting or leading equipment deployment across multiple lines, programs, or facilities.
• Strong understanding of core engineering principles applied to production systems, with demonstrated ability to apply them at scale.
• Demonstrated ability to troubleshoot complex electromechanical equipment and lead others through technical problem-solving.
• Experience mentoring or informally leading other engineers or technicians.
• Ability to travel between facilities and supplier locations as required.

Preferred Skills

• Experience with cycle time modeling, bottleneck identification, and throughput optimization.
• Proficiency with DOE, SPC, Cp/Cpk analysis, Gage R&R, and real-time data monitoring.
• Understanding of OEE tracking, yield analysis, and defect reduction methods.
• Familiarity with PLCs, HMIs, SCADA, safety circuits, and automation debugging.
• Knowledge of servo systems, pneumatics, vacuum systems, and motion tuning.
• Experience leading FAT/SAT, commissioning, validation, and equipment acceptance.
• Background in predictive maintenance, reliability engineering, and structured downtime analysis.
• Proficiency in line balancing, takt time planning, ergonomic workstation design, and process documentation.
• Experience with PFMEA, control plans, PFDs, and end-to-end process mapping.
• Supplier qualification experience including audits and vendor management.
• Strong RCA skills using 8D, A3, DMAIC, Ishikawa, and Five Whys methodologies, with experience teaching these methods to others.
• Knowledge of forging, CNC machining, heat treatment, welding, and mechanical assembly processes.
• Experience standardizing processes or equipment specifications across multiple sites or business units.