Lead Manufacturing Engineer

Aptiv; Garden Grove (CA); On-site; USD 130,000 - 165,000; Full time

Benefits offered by this job

Health coverage

401(k) with company match

Paid time off

Career development resources

Job summary

Aptiv Interconnect in Garden Grove, CA is hiring a Senior Manufacturing & Process Engineer to optimize and scale high-mix, low-volume aerospace and defense production. You will lead PFMEA, SOP/WO governance, and customer-facing technical discussions to ensure processes meet specifications and quality targets.

You will mentor engineers, collaborate with design and manufacturing teams, and drive continuous improvement through Lean and Six Sigma methods in a regulated environment.

Qualifications

• Bachelor's degree in Mechanical, Manufacturing, or Electrical Engineering or related field.
• Minimum 7+ years in process/manufacturing engineering in a high-precision or regulated environment.
• Experience with MIL-DTL, IPC/WHMA-A-620, AS9100/ISO9001, and quality systems is preferred.

Responsibilities

• Lead process optimization and QA initiatives to reduce cycle times and waste.
• Act as SME in customer meetings, design reviews, and audits.
• Develop and maintain SOPs, CPs, and PFMEA documentation.
• Support NPI with DFM/DFA input and readiness reviews.

Skills

7+ years experience

Aerospace/defense domain

US ITAR compliance

Lean/Six Sigma

Technical presentation skills

Documentation writing

Education

Bachelor's degree in Mechanical/Manufacturing/Electrical Engineering

Tools

SolidWorks

AutoCAD

ERP/MRP systems

Syspro

Job description

We always do the right thing, the right way.

Job Title: Senior Manufacturing & Process Engineer

Location: 12691 Monarch Street, Garden Grove, CA 92841 USA

Department: Engineering

Reports To: Engineering Manager

Job Type: Full-Time

Compensation: $130,000 - $165,000 per year + 10% AIP

Summary: At Aptiv Interconnect, we inspire the world’s most innovative teams by doing the right thing, the right way. We are seeking a Senior Manufacturing & Process Engineer to act as a pivotal bridge between our technical engineering operations and our key client stakeholders. You will be responsible for evaluating, optimizing, and scaling manufacturing processes to improve production efficiency, product quality, and cost savings in a high-mix, low-volume aerospace and defense manufacturing environment. As a senior team member, you will leverage extensive process engineering expertise to solve complex technical challenges, establish rigorous process documentation, and lead customer‑facing technical discussions to ensure production capabilities align seamlessly with customer specifications. You will play a vital role in ensuring that our products consistently meet the rigorous standards of the space, defense, and industrial markets we serve.

Leadership & Core Responsibilities

Process Optimization & Quality Assurance

• Assess existing production processes, identify bottlenecks, reduce cycle times, eliminate waste, and implement Lean/Six Sigma continuous improvement initiatives across the facility.
• Lead complex troubleshooting for internal and external quality escapes, utilizing root cause analysis methods (5-Why, Fishbone, 8D, CAPA) to implement permanent and robust solutions in collaboration with the Quality team.
• Author, revise, and continuously improve robust process documentation, including Standard Operating Procedures (SOPs), Work Instructions (WIs), Manufacturing Process Specifications, and Control Plans within the ERP system.
• Lead and maintain Process Failure Mode and Effects Analysis (PFMEA) activities to proactively identify and mitigate manufacturing risks.
• Oversee process validation protocols and ensure all engineering processes and documentation comply with applicable industry standards including MIL-DTL, IPC/WHMA-A-620, AS9100, and customer‑specific requirements.

Technical Collaboration & Engineering Leadership

• Serve as the primary technical subject matter expert (SME) during customer meetings, design reviews, technical audits, and engineering site visits.
• Collaborate directly with customer engineering teams on Design for Manufacturability (DFM) and Design for Assembly (DFA) feedback to ensure smooth transitions during the New Product Introduction (NPI) process.
• Mentor and develop junior engineers and manufacturing engineers, elevating the technical capability of the team through hands‑on coaching and knowledge sharing.
• Support the commercial team by providing timely and accurate technical input, labor estimates, and process recommendations to improve quote quality and turnaround.
• Comply with all company policies and procedures.
• Perform other duties as assigned.

Position Requirements

Education & Technical Qualifications

• Education: Bachelor's degree in Mechanical Engineering, Manufacturing Engineering, Electrical Engineering, or a related technical discipline.
• Experience: Minimum 7+ years of progressive experience in process or manufacturing engineering within a high-precision or regulated manufacturing environment (aerospace, defense, or space applications preferred).
• Industry Domain: High-precision or regulated manufacturing environment. Familiarity with cable assembly design, manufacturing processes, connector systems, and testing protocols including MIL-DTL specifications is highly desired. Understanding of industry workmanship standards including IPC/WHMA-A-620 and J-STD-001. Experience working under AS9100 and ISO9001 quality management systems.
• Regulatory Compliance: Must be a U.S. Person (U.S. Citizen or Permanent Resident) due to ITAR regulations.

Certifications & Competencies

• Certifications: IPC certification is strongly preferred. Six Sigma Green Belt or Black Belt certification strongly preferred.
• Systems Proficiency: Proficiency in 2D/3D CAD software (e.g., SolidWorks, AutoCAD) and ERP/MRP systems; Syspro experience is a plus. Systems used: Google Workspace, SmartView, Salesforce, ADP, Syspro, QMS, Planful, and AwardCo.
• Core Competencies: Demonstrated mastery of Lean Manufacturing tools (Kaizen, 5S, VSM, Poka‑Yoke). Proven track record of leading technical presentations, managing client expectations, and handling customer‑driven design and production reviews. Exceptional technical writing skills. Outstanding verbal and written communication skills with the ability to convey complex engineering concepts across all levels of the organization, including customers and program teams.

Compensation, Benefits & Legal

Total Rewards & Compensation

Base Salary Range: $130,000 – $165,000 per year, based on experience and qualifications.

Incentive Compensation: 10% AIP

Benefits & Perks: Employees receive a comprehensive benefits package featuring health coverage, 401(k) with company match, paid time off, and career development resources.

EEO Statement

Equal Opportunity Employer/Protected Veterans/Individuals with Disabilities. In addition to federal law requirements, Winchester Interconnect complies with applicable state and local laws governing nondiscrimination in employment in every location in which the company has facilities. Winchester Interconnect expressly prohibits any form of workplace harassment based on race, color, religion, gender, sexual orientation, gender identity or expression, national origin, age, genetic information, disability, or veteran status.