Kratos Defense and Security Solutions

Senior Manufacturing/Process Engineer (Prometheus Energetics)

Kratos Defense and Security Solutions • $90K — $120K *
Bloomington, IN 47401In-Person
Aerospace & Defense
5 - 7 years of experience
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Job Overview by Ladders

Qualifications

  • Bachelor's degree in Mechanical, Aerospace, or Manufacturing Engineering.
  • 6+ years in manufacturing, process, or tooling engineering in aerospace and defense.
  • Proficient in 3D CAD software and PDM/PLM systems.
  • Strong knowledge of GD&T, material strength, and metal fabrication methods.
  • Experience with assembly routers, process diagrams, and work instructions.
  • Excellent communication skills, both verbal and written.
  • U.S. citizenship and ability to obtain a Secret Security Clearance.

Responsibilities

  • Establish and sustain manufacturing processes and standard work instructions for rocket motor production.
  • Analyze operational flows to optimize throughput and reduce cycle times.
  • Provide troubleshooting and technical guidance to shop-floor operators.
  • Collaborate with tooling engineers to develop production tooling and molds.
  • Define specifications for capital equipment and manage its integration into production.
  • Evaluate non-conforming hardware and implement corrective actions as part of the MRB.
  • Drive continuous improvement using Lean/Six Sigma and other methodologies.

Benefits

  • Health, dental, and vision insurance.
  • 401(k) retirement plan with company match.
  • Paid time off and holidays.
  • Opportunities for career advancement and continuing education.
  • Support for obtaining and maintaining required security clearances.
Full Job Description
Position Summary

Prometheus Energetics is seeking an experienced Senior Manufacturing & Process Engineer to serve as a critical technical authority as our Bloomington operations transition from facility startup and product industrialization into high-rate production.

In this role, you will bridge product design and shop-floor execution. You will own the manufacturing processes, standard work instructions, production line layouts, and specialized energetic tooling integration required to build tactical solid rocket motors and warheads safely and efficiently. Working closely with Engineering, Operations, Quality, EHS, and strategic partner technology-transfer teams, you will ensure that energetic mixing, casting, curing, machining, and final assembly operations satisfy all technical, quality, safety, and customer performance requirements.

Key Responsibilities

Process Engineering & Shop Floor Integration
  • Establish, prove out, and sustain manufacturing processes, operational routers, tooling sheets, and detailed Standard Work Instructions (SWIs) for solid rocket motor (SRM) cast/cure, propellant handling, motor assembly, and energetic packaging operations.
  • Analyze operational flows, workstation ergonomics, and line balance to optimize throughput, reduce cycle times, and support rapid production scaling.
  • Serve as the primary manufacturing engineering contact for shop-floor operators and technicians, providing real-time troubleshooting, guidance, and technical direction on active production lines.

Tooling Architecture & Capital Equipment
  • Partner with Tooling Engineers to translate product design requirements and energetic process constraints into robust, safe, and reliable production tooling, molds, fixtures, holding C-frames, and rotation carts.
  • Define capital equipment specifications, evaluate vendor technical proposals, and manage full-lifecycle acquisition and integration of specialized manufacturing machinery.
  • Lead on-site equipment installation, proof loading, line buy-off, and operational validation prior to releasing equipment into active energetic production.

Non-Conformance, MRB & Continuous Improvement
  • Act as an active voting member on the Material Review Board (MRB) to evaluate non-conforming hardware, perform engineering dispositions, and implement containment protocols.
  • Lead formal Root Cause Corrective Action (RCCA) investigations for hardware non-conformances, process escapes, and tooling wear using 5-Why, Fishbone, and 8D methodologies.
  • Drive continuous improvement and high first-pass yield using Lean/Six Sigma practices, Process Failure Mode and Effects Analysis (PFMEA), Statistical Process Control (SPC), and mistake-proofing (poka-yoke) controls.

Explosive Safety, ESD & Compliance
  • Partner with Environmental Health & Safety (EHS) and Energetics Safety teams to strictly enforce site-specific explosive safety standards (e.g., DoD 4145.26-M), Electrostatic Discharge (ESD) controls, and OSHA guidelines across all equipment and processes.
  • Ensure full compliance with AS9100 quality standards, Nadcap requirements, customer drawing specifications, and federal ammunition and explosives regulations.

Performance Management

Establish actionable dashboards, review tooling performance with engineering and operational leadership, and hold owners accountable for recovery and improvement plans. Measures may include:
  • Process design-to-release schedule compliance and milestone execution
  • Vendor quality, delivery performance, and technical drawing compliance for equipment and tooling
  • Process-and tooling-related scrap, rework, cost of poor quality, and first-pass yield impact
  • Root-cause investigation aging, recurrence prevention, and RCCA effectiveness
  • Equipment proof-load, calibration, and maintenance plan compliance
  • Explosive safety, ESD, and ergonomic compliance across all active processing assets
  • Manufacturing team capability, technical development, and program support effectiveness


Required Qualifications
  • Bachelor's degree in Mechanical Engineering, Aerospace Engineering, Manufacturing Engineering, or a related technical discipline.
  • Minimum of 6+ years of progressive manufacturing, process, or tooling engineering experience in an aerospace and defense hardware manufacturing environment.
  • Proficiency in 3D CAD software (e.g., PTC Creo, Siemens NX, SolidWorks) and Product Data Management (PDM/PLM) systems (e.g., Windchill).
  • Solid understanding of Geometric Dimensioning and Tolerancing (GD&T per ASME Y14.5), structural strength of materials, and precision metal fabrication methods.
  • Proven experience generating assembly routers, process flow diagrams, PFMEAs, and detailed work instructions from complex engineering drawing packages.
  • Excellent written, verbal, analytical, and executive communication skills.
  • U.S. citizenship and the ability to obtain and maintain a U.S. Government Secret Security Clearance.

Preferred Qualifications
  • Master of Science in Mechanical Engineering, Aerospace Engineering, or Engineering Management.
  • Direct experience in solid rocket motor manufacturing, propellant casting/curing, warheads, pyrotechnics, ammunition, or high-hazard chemical/energetic processing.
  • Hands-on familiarity with press tooling, hydraulic/pneumatic actuation systems, automated handling carts, and optical/CMM metrology systems.
  • ASQ certifications (CQE, CQA), formal GD&T certification, or Six Sigma Green/Black Belt credentials.
  • Prior experience standing up manufacturing lines or integrating new production facilities in a startup or rapid defense expansion environment.
  • Active U.S. Secret Security Clearance or higher.

About Kratos Defense and Security Solutions

Kratos Defense & Security Solutions, Inc. provides mission critical products, solutions, and services in the United States. The company operates through three segments: Kratos Government Solutions, Unmanned Systems, and Public Safety & Security. The Kratos Government Solutions segment offers microwave electronic products, satellite communications, training systems, modular systems, and defense and rocket support services. The Unmanned Systems segment provides unmanned aerial, ground, and seaborne, as well as command, control, and communications systems. The Public Safety & Security segment designs, engineers, deploys, operates, integrates, maintains, and operates security and surveillance solutions for homeland security, public safety, critical infrastructure, government, and commercial customers. The company serves national security related agencies, the department of defense, intelligence agencies, and classified agencies, as well as international government agencies and domestic and international commercial customers; and critical infrastructure, power generation, power transport, nuclear energy, financial, IT, healthcare, education, transportation, and petro-chemical industries, as well as government and military customers. Kratos Defense & Security Solutions, Inc. was founded in 1994 and is headquartered in San Diego, California.
Learn more about Kratos Defense and Security Solutions
Size
3,300 employees
Market Cap
$1.1 billion
Industry
Aerospace & Defense
Net Income
$79.6 million
Founded
1994
5 Year Trend
+8.4%
Revenue
$747.6 million
NASDAQ
KTOS
* Ladders Estimates

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