SUMMARY As part of a small, fast-paced, and passionate team you will lead the machine shop manufacturing engineering function responsible for driving rocket component production at scale. You will lead a team of manufacturing engineers who serve as the critical link between the machine shop floor and the engineering team. You will be accountable for developing, optimizing, and scaling CNC machining processes for 3-, 4-, and 5-axis machines that produce critical components for Alpha, Eclipse launch vehicles and Blue Ghost and Elytra spacecraft. Input provided by your team can determine the success or failure of individual components, assemblies, and ultimately our production ramp. This position is located at our Manufacturing and Test site in Briggs, TX, north of Cedar Park.
RESPONSIBILITIES - Lead and mentor a team of manufacturing engineers supporting machine shop operations and act as the primary liaison between the machine shop and the engineering team
- Translate engineering design requirements into formal manufacturing process documentation including raw material definition, fixturing/tooling development, CNC programming strategies, inspection planning, and finishing requirements
- Provide feedback to responsible engineers and ensure the most time-efficient and cost-efficient method of producing components
- Drive continuous process development and improvement with the aim of radically increasing production rate and substantially reducing cost through data analysis, application of best practices, and innovative solutions
- Ensure on time delivery of rocket components from CAD models to tangible components/assemblies ready for testing
- Develop and implement digital work instructions and inspection sheets to guide operators and integrate with quality management systems (QMS)
- Lead the development, test, and qualification of new machining processes and drive equipment commissioning
- Mentor members of the team through investigations of process failures, troubleshooting machining challenges, and drive corrective actions to closure
- Work with Tooling and Programming teams to ensure job readiness and optimize CNC programs using machining modeling and analysis tools
- Manage lookaheads for long lead tasks and work closely with production teams to manage build schedules
- Research new manufacturing methods, production related processes, and materials for improved production efficiency and final product performance
- Be fully accountable for hardware sets and establish clear ownership within the team
- Improve processes and cycle times, implement quick changeover improvements, and drive strategic initiatives to ensure team is operating with the most innovative manufacturing capabilities
- Establish and implement standards for tooling and fixturing design, review, and commissioning
- Own and maintain Manufacturing controls within Firefly's Enterprise Resource Planning software
- Participate in design reviews to drive design-for-manufacturing initiatives, ensure manufacturability of components, and implement lessons learned
- Participate in the Production Part Approval Process (PPAP) by developing and validating manufacturing processes and tooling
- Identify issues, work with quality assurance to provide and execute corrective actions, and establish standards for manufacturing readiness reviews and production hand off
- Provide direct floor-support to machine shop for continuous production and train shop floor personnel on new procedures
QUALIFICATIONS Required - Bachelor's degree in Engineering or related technical field, or 7+ years of experience working in a machine shop environment implementing the aforementioned responsibilities
- 7+ years' professional work experience with CNC machining and manufacturing complex components
- 3+ years of engineering leadership experience
- Expert level understanding of GD&T and familiarity with ASME Y14.5
- Strong knowledge of CNC machining processes, high-speed machining techniques, cutting tool technology, and machine tool capabilities
- Experience developing CNC machining programs for metal parts on multi-axis machines
- Experience working with Inconel and other difficult to machine materials
- Experience with CAD software such as Pro-E, CATIA, Autodesk Inventor, SolidWorks, or NX
- Ability to develop CAD models and create engineering drawings per international drawing standards
- Able to read and interpret technical drawings and manufacturing documentation
- Proven mechanical aptitude and hands-on problem-solving skills in a production environment
- Exceptional people interaction skills and strong interpersonal and conflict resolution skills Must be a team player
- Excellent written and verbal communication skills
- A passion for creating, building, and making things happen
- Proven experience with tasks requiring extreme attention to detail and prolonged mental concentration
- Ability to thrive in high stakes, stressful, short deadline environments
- Critical thinking and strong decision making ability
- Demonstrated results with scaling up business operations
- Proven demonstration of acting as process-oriented change agent
- Familiarity with AS9100 or ISO 9001 quality standards
- Experience writing machining procedures, work instructions, and test plans
Desired - Proven experience leading teams and providing mentorship in a manufacturing environment
- Experience with modern manufacturing principles, such as Lean Manufacturing, Six Sigma, PFMEA, and SPC
- Experience with CAM software (Mastercam, Siemens NX, or similar)
- Experience with program validation tools such as CGTech Vericut or CIMCO Edit
- Direct experience with process development in casting, forging, metallic 3D printing, and sheet metal
- Experience programming and setting up CNC machines
- Experience with Vertical Turn Lathes
- Experience Macro programming
- Experience with digital manufacturing tools, Industry 4.0 technologies, and electronic work instructions
- Knowledge of data analysis packages (Python/high level Excel)
- Experience with shop floor process monitoring, data collection, and adaptive methods
- Experience with budgetary and schedule planning, and capacity planning
- Demonstrated working knowledge of manufacturing ERP, MRP, or similar manufacturing software systems
- Startup experience
- Aerospace or space systems manufacturing experience
*Relocation Assistance
Firefly offers outstanding benefits for our employees, including generous health, dental and vision plans with low plan deductibles, parental leave, educational reimbursement, short term disability, and flexible PTO options. To conform to U.S. Government space technology export regulations, including the International Traffic in Arms Regulations (ITAR) you must be a U.S. citizen, lawful permanent resident of the U.S., protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain the required authorizations from the U.S. Department of State.
