As we scale production, we are seeking a Senior Director of Sustaining Manufacturing Engineering to lead the industrialization, launch, and continuous improvement of our drone platforms. This role will ensure our products are manufacturable, testable, reliable, and continuously improving as we scale volume and complexity.

What You'll Do

• Lead all sustaining and NPI manufacturing engineering deliverables and functions to support the transition from development to scalable production and ongoing optimization.
• Build and lead a multidisciplinary team spanning manufacturing, industrial, test, and equipment engineering, working in close partnership with the Manufacturing Systems & Automation team.
• Drive NPI manufacturing readiness for new sUAS platforms providing early DFX input to Core Engineering, and lean process development to ensure pilot production readiness including manufacturing specs, BOMs, workflow, work instructions, tools and fixtures, assembly & test equipment, training, and process validation.
• Define and support NPI stage gates through the PLC (Concept/ Pilot/ EVT/ DVT/ PVT/ GA/ EOL) including direct support of proto and pilot builds to ensure production quality, throughput, traceability, and cost targets are met.
• Partner with Core Engineering to incorporate DFX to eliminate design-driven manufacturing risks early, and own sustaining design improvements to reduce costs, improve high-volume production.
• Own production process yield, throughput, cycle times, labor efficiency, line optimization, cost, and manufacturability across multiple product lines.
• Lead continuous improvements to production per data analytics,6-sigma, and lean methods to ensure assembly and test capacity scales to meet demand.
• Drive improvements for safety / ergo, quality, yield, throughput, delivery, and cost by employing data-driven, lean methods.
• Drive tools, fixtures, jigs for new and existing processes, and collaborate with Manufacturing Systems and Automation to deploy assembly and inspection equipment for manual, and semi-automated and fully automated processes
• Support the development and own sustainment of functional sub-system and system tests for production.
• Drive MES selection, integration with ERP, QMS and PLM; including test equipment and data integration, data analytics, automated reporting, and training and deployment of augmented reality (AR) work instructions into production.
• Build capacity models, staffing plans, labor standards, throughput optimization, and ramp plans.
• Support new equipment selection, development, commissioning, and sustaining maintenance (TPM) through its lifecycle to ensure required OEE.
• Support domestic outsourcing & contract manufacturing by ensuring transfer readiness (docs, processes, equipment, standards, training, ongoing alignment).
• Build, and develop a data-driven, hands-on, and accountable team of manufacturing engineers, technicians, TPMs, and managers.
• Partner with cross-functionally to support NCR disposition, CAPA, compliance, product improvements, and drive operational excellence.
• Support Supply Chain and Quality for materials readiness, and supplier quality, and act as the technical bridge between product design and factory execution.

Requirements

• Bachelor's degree in Engineering (Mechanical, Electrical, Manufacturing, Aerospace) or applicable technical discipline. Master's degree (MS/MBA) a plus.
• 15+ years of hands-on manufacturing engineering leadership experience in high-growth, high-volume manufacturing environments using Lean / Six Sigma methods.
• Proven track record leading NPI and scaling processes and tools to HV production; preferably in either sUAS, robotics, consumer electronics, or aerospace / defense.
• Strong experience developing assembly and test processes, complex system integration (HW+FW/SW), MES integration of test data and data analytics.
• Strong background in DFM/DFA/DFT, commissioning and sustaining semi-auto and automated production, and employing lean manufacturing.
• Seasoned in NPI readiness, process capability, employing Lean / Six Sigma methods to optimize yield, throughput, cycle time, labor efficiency, cost, and OEE.
• Experience integrating enterprise systems (MES, ERP, QMS, PLM, EAM/CMMS) for traceability, NCR, CAPA, genealogy, data collection / analytics, and compliance; including real-time production monitoring (OEE, yield, down-time, CT, etc.)
• Experience supporting manufacturing equipment and data sources (PLC/OPC UA/SCADA, IIoT/edge) and enterprise systems (APIs, middleware/iPaaS).
• Master data governance and change control (MBOMs, routings, PN/revs) and manufacturing specification documentation.
• Experience building and scaling teams across multiple disciplines and managing managers and technical leads.
• Strong execution mindset with ability to operate in fast-paced environments with positive, servant-leadership.
• Working knowledge of OT/IT cybersecurity practices in manufacturing environments.
• Vendor and program management (business cases, SOWs, SLAs, budgets, reports) and executive-level communication.
• Eligible to obtain and maintain a U.S. Secret security clearance

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 as well as manufacturing and test equipment, industrial computers, HMIs, and handheld diagnostic tools. Must be physically capable of walking production floors, accessing equipment in constrained spaces, participating in factory acceptance testing, and supporting on-site system deployments.

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 manufacturing equipment, automated machinery, test systems, and industrial materials. 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 work hours for this position are full-time, Monday through Friday, 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.
• On-site gym at our Huntsville, AL location.
• Employer provided life insurance.
• Robust Employee Assistance Program (EAP).
• A work environment that encourages teamwork and innovation.
• Competitive salary, generous paid time off (PTO), and flexible leave options.