Application close date:
Applications will be accepted on an ongoing basis until the requisition is closed.

This role is part of Blue Origin Operations, which is comprised of Integrated Supply Chain, Test Operations, Safety, Quality, and Mission Assurance. This includes Manufacturing and Supply Chain support across all Blue Origin facilities.

Blue Origin's Emerging Systems business unit is building TeraWave, a satellite communications constellation powered by the most advanced optical communications architecture ever attempted: thousands of optically interconnected satellites delivering symmetrical data speeds of up to 6 Tbps anywhere on Earth, providing enterprise and hyperscale customers with resilient, scalable connectivity for critical operations where terrestrial infrastructure cannot reach.

As a Senior Manufacturing Process Flow & Control DFX Engineer, you will own the end-to-end manufacturing process flow and process control design integration for TeraWave production - bridging production line architecture, process control systems, and volume production readiness. As a foundational element of TeraWave operations, hardware must be produced through process flows architected not only for throughput but for manufacturability, testability, reliability, and serviceability at constellation scale. This is a hands-on role for an engineer who has designed, optimized, and scaled complex manufacturing process flows and control systems in fast-moving, high-volume manufacturing environments and wants to apply that experience to hardware operating at orbital scale.

Special Mentions:

• Relocation assistance is available for qualified candidates.
• Travel: Up to 50%.

Responsibilities:
Process Flow & Control Design, Integration & Manufacturing

• Lead manufacturing process flow design for satellite modules and subsystems: production line architecture, workflow sequencing, station design, takt time optimization, and material flow.
• Own process control development - including statistical process control (SPC), process monitoring, traveler and work instruction systems, MES integration, and data collection workflows - to ensure robust, repeatable production.
• Manage process documentation, routing definition, capacity planning, vendor and internal coordination, and production line oversight.
• Drive process validation, control plan development, first-article and production readiness reviews to support production ramp.

Design for Excellence (DFX)

• Drive Design for Excellence (DFX) principles - DFM, DFT, DFA, DFR, and DFS - across the full manufacturing process flow and control lifecycle to ensure hardware scales from prototype through volume production for TeraWave operations.
• Design for Manufacturability (DFM): Optimize process sequencing, station layout, and workflow design to maximize yield, throughput, and minimize cost at constellation-scale production volumes.
• Design for Test (DFT): Architect in-line test and inspection points, data capture, and process monitoring to enable efficient factory acceptance, traceability, and in-field diagnostics.
• Design for Assembly (DFA): Simplify process steps, minimize handoffs, and optimize station design to reduce cycle time, rework, and error rates across the line.
• Design for Reliability (DFR): Apply process FMEA, control plans, statistical process control, and reliability prediction to ensure consistent, defect-free production supporting long-duration operation in the orbital environment.
• Design for Serviceability/Supply Chain (DFS): Coordinate with supply chain and manufacturing partners to align process flows with material availability, standardization, and obsolescence mitigation across the production lifecycle.
• Partner with manufacturing, quality, and supply chain teams to define acceptance criteria, drive yield and throughput optimization, and support production ramp for sustained TeraWave operations.

Minimum Qualifications:

• Bachelor's degree in Industrial Engineering, Manufacturing Engineering, Mechanical Engineering, or a related field.
• 10+ years of experience in manufacturing process engineering, process flow design, or production control in a product development and volume production environment.
• Experience designing and optimizing manufacturing process flows, line balancing, and process control systems for complex hardware.
• Hands-on experience with statistical process control (SPC), process FMEA, control plans, MES/ERP systems, and production line bring-up.
• Demonstrated application of DFX principles (DFM/DFT/DFA/DFR) in bringing process flows from design into volume production.
• Excellent technical documentation and communication skills.

Preferred Qualifications:

• Master's degree in Industrial, Manufacturing, or Mechanical Engineering.
• 15+ years of relevant experience.
• Lean Six Sigma certification (Green Belt or Black Belt) or equivalent process improvement expertise.
• Experience with high-mix or high-volume production line design, automation integration, and Industry 4.0 / smart factory concepts.
• Experience developing process flows for space, aviation, or other high-reliability manufacturing environments.
• Experience with capacity modeling, simulation, and throughput analysis tools.
• Background in production hardware including comprehensive DFX practices (DFM/DFT/DFA/DFR), process optimization, supply chain coordination, and yield optimization at scale.
• Hands-on experience with production ramp and factory scale-up.

Base Pay Range for:
CA applicants is $156,802.00 - $219,522.45

Other site ranges may differ

Benefits

• Benefits include: Medical, dental, vision, basic and supplemental life insurance, paid parental leave, short and long-term disability, 401(k) with a company match of up to 5%, and an Education Support Program.
• Stock Options for all regular employees (working at least 20 hours/week)
• Paid Time Off: Up to four (4) weeks per year based on weekly scheduled hours, and up to 14 company-paid holidays.
• Dependent on role type and job level, employees may be eligible for benefits and bonuses based on the company's intent to reward individual contributions and enable them to share in the company's results, or other factors at the company's sole discretion. Bonus amounts and eligibility are not guaranteed and subject to change and cancellation. Please check with your recruiter for more details.