Senior Staff Engineer, Advanced Manufacturing

About the role

Shield AI is seeking a senior engineering leader to own critical manufacturing processes across multiple programs. You will build the infrastructure for a new production line supporting a next‑generation jet, selecting capital equipment, deploying hardware and software tools, and establishing robust production systems. The role blends cross‑functional impact, technical leadership, and factory‑scale execution.

Key responsibilities

• Define the Bill of Process and manufacturing sequence for assigned subassemblies or cells.
• Map MBOM to operations, tooling needs, and process controls.
• Build ergonomic workstations with calibrated torque tools, ESD controls, and material handling zones.
• Create visual, operator‑ready work instructions with torque specs, PPE requirements, inspection points, and MES revision control.
• Conduct time studies, compute takt and cycle time, identify bottlenecks and lead Kaizen improvements.
• Establish standardized work, visual controls, job aids and layered audit systems, iterating with operators.
• Capture shop‑floor lessons, drive root‑cause analysis and corrective actions.
• Partner with Quality on in‑process checks, error‑proofing and first‑article inspection readiness.
• Implement engineering change orders, validate process updates and maintain work instructions.
• Select and deploy capital equipment for the new jet production line.
• Mentor other engineers and facilitate cross‑functional integration.

Required profile

• 10+ years of experience in manufacturing engineering, production systems or assembly engineering.
• Bachelor’s degree in Mechanical, Industrial, Mechatronics or related STEM field.
• Experience in prototype manufacturing within a startup or rapid‑growth environment.
• Strong understanding of machining, composites, avionics and assembly processes.
• Proven ability to thrive in fast‑paced, high‑pressure settings and adapt to changing priorities.
• Knowledge of quality standards such as AS9100 or ISO 9001 (preferred).
• Proficiency in CAD software (preferred).
• Familiarity with advanced manufacturing technologies such as additive manufacturing or automation systems (preferred).

Required skills

• MES/QMS systems
• Torque analyzers
• Minitab and Excel for SPC, capability studies and DOE
• Lean manufacturing and 5S methodologies
• PFMEA and control plan development
• Ergonomic assessment tools
• Standard Operating Procedures creation
• CAD software (preferred)
• Additive manufacturing and automation systems (preferred)