Senior Manufacturing Engineer

Category: Business Analysis (functional and technical)

Main location: United States, Maryland, Huntsville

Position ID:J0626-0880

Employment Type: Full Time

Position Description:

CGI Federal is seeking a Senior Manufacturing Engineer responsible for driving advanced manufacturing planning, production readiness, and engineering-to-manufacturing integration for modernization efforts across a Next Generation Command and Control (NGC2) program for the US Army. This role ensures that designs are manufacturable, compliant with military specifications, cost-effective, and optimized for quality and repeatability. The Senior Manufacturing Engineer serves as a technical leader who partners closely with engineering, configuration management, quality assurance, and suppliers to develop manufacturing processes that support modern production standards and evolving Defense requirements.

This position is located in Huntsville, AL.

Your future duties and responsibilities:

Manufacturing Planning & Process Development
. Develop advanced manufacturing plans, tooling requirements, and build strategies
. Define manufacturing processes that ensure quality, repeatability, and compliance with Defense requirements
. Translate engineering designs into efficient production workflows and work instructions
. Conduct manufacturability assessments and recommend design modifications to improve production efficiency
Engineering Integration
. Work closely with design engineers to interpret technical drawings, models, and specifications
. Evaluate engineering change proposals and support change incorporation into manufacturing baselines
. Collaborate with CM, quality, and program teams to maintain configuration discipline in production
Material & Product Design Support
. Lead raw material selection, supplier evaluations, and material certification processes
. Ensure materials and components comply with military standards, specifications, and environmental requirements
. Identify opportunities for material optimization and cost reduction
CAD/CAM & Digital Manufacturing Tools
. Utilize CAD/CAM systems to develop toolpaths, model manufacturing fixtures, and support design for manufacturability
. Support implementation of digital manufacturing tools, model-based work instructions, and advanced technical data packages
. Maintain accuracy of digital build data and integrate updates throughout the product lifecycle
Production Readiness & Oversight
. Support first article builds, prototype development, and build verification activities
. Diagnose production issues and implement corrective and preventive actions
. Develop documentation including manufacturing plans, process sheets, routing instructions, and traveler documentation
. Support supplier manufacturing readiness reviews and on-site production audits
Quality & Compliance
. Ensure manufacturing processes comply with military specifications, industry standards, and quality control requirements

Required qualifications to be successful in this role:

Required qualifications to be successful in this role:
Education
. MA/MS degree in Industrial Engineering, Manufacturing Engineering, or related field with 8 years experience
. Degree substitution options:
- One academic year of related accredited coursework may substitute for one year of experience
- BA/BS + 11 years of experience may substitute for the graduate degree
- No degree: must have over 17 years of experience may substitute for the degree requirement
Experience
. Experience in a manufacturing environment supporting Defense systems
. Experience developing manufacturing processes, workflows, and planning packages
. Experience interpreting technical drawings, specifications, and engineering models
. Experience involving materials selection, certification, and production documentation
. Familiarity with engineering change processes and design modification workflows
Technical Skills
. Proficiency in CAD/CAM systems and digital technical data
. Strong understanding of military specifications, standards, and certification requirements
. Experience with manufacturing process development, tooling, and fixture design
. Ability to support production troubleshooting and process control improvements
Leadership & Communication
. Ability to collaborate across engineering, production, quality, supply chain, and program teams
. Experience preparing and presenting manufacturing analysis, process updates, and readiness assessments
. Ability to mentor junior engineers or technicians in manufacturing processes
Desired qualifications/non-essential skills required:
Advanced Manufacturing Expertise
. Experience with additive manufacturing, automated machining, or advanced fabrication methods
. Familiarity with model-based engineering and digital thread/digital twin environments
. Experience with set-up reduction, lean manufacturing, and workflow optimization
Tools & Systems Knowledge
. Experience with PLM/MRP/ERP systems such as SAP, Windchill, Teamcenter, or equivalent
. Knowledge of process simulation or manufacturing optimization tools
. Experience with statistical process control (SPC) and automated inspection technology
Certifications
. SME certifications (CMfgE, CMfgT, or similar)
. DAWIA or FAC-ENG related certifications (optional but beneficial)
Additional Skills
. Strong root cause and corrective action (RCCA) analysis skills
. Experience supporting first article inspections (FAI) and supplier qualification
. Ability to manage production readiness risks and develop mitigation plans

CGI is required by law in some jurisdictions to include a reasonable estimate of the compensation range for this role. The determination of this range includes various factors not limited to skill set, level, experience, relevant training, and licensure and certifications. To support the ability to reward for merit-based performance, CGI typically does not hire individuals at or near the top of the range for their role. Compensation decisions are dependent on the facts and circumstances of each case. A reasonable estimate of the current range for this role in the U.S. is $89,600.00 - $198,400.00.
CGI Federal's benefits are offered to eligible professionals on their first day of employment to include:
. Competitive compensation
. Comprehensive insurance options
. Matching contributions through the 401(k) plan and the share purchase plan
. Paid time off for vacation, holidays, and sick time
. Paid parental leave
. Learning opportunities and tuition assistance
. Wellness and Well-being programs
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Skills:

• Concept Design
• Defense
• Functional specification
• Manufacturing
• Military