Manufacturing Engineer, Sr.

AeroVironment, Inc.; Petaluma (CA); On-site; USD 123,000 - 187,000; Full time

Job summary

AeroVironment, Inc. is seeking a Sr. Manufacturing Engineer to design and operate the manufacturing systems for its Unmanned Air Vehicles.

The role focuses on selecting optimal technologies, planning the factory, and driving maintenance and continuous improvement of processes. The candidate will lead manufacturing strategy, cost estimation, and collaboration with design engineers and suppliers to ensure high-quality, efficient production, while applying Lean and Six Sigma to improve productivity

Qualifications

• Bachelor's degree in Mechanical, Electrical or similar field required.
• 8–12 years of experience in Manufacturing, Mechanical, Electrical, Test Engineering or similar in Aerospace, Automotive, or Commercial industries.
• Experience with Lean Manufacturing and Six Sigma methodology required.
• Experience with electro‑mechanical manufacturing, drawings, procedures and Bills of Materials required.
• Proficient with Microsoft Office suite and CAD programs (SolidWorks preferred).
• Up to 30% travel to supplier sites.

Responsibilities

• Creates and manages equipment specifications and documentation for development, qualification and support of assembly and test equipment for production.
• Implements Lean Manufacturing principles and applies Six Sigma to improve productivity, quality, and lead time.
• Generates Value Stream Maps to reduce cycle time, waste and variation.
• Develops manufacturing strategies and capacity models for new and existing products, including capital expenditure estimates.
• Produces and reviews work instructions, assembly procedures and documentation controlling the manufacturing process.
• Cost estimating of tooling and fixtures to support production.
• Leads Make/Buy analysis on assemblies with cross-functional teams.
• Performs design for manufacturing, cost and reliability analysis with design engineering.
• Coordinates with suppliers and contract manufacturers to ensure conforming parts.

Skills

Lean Manufacturing

Six Sigma

Root cause analysis

Cross-functional collaboration

Education

Bachelor's degree in Mechanical, Electrical or similar field

Tools

SolidWorks

MiniTab

Microsoft Office

Oracle

CAD tools

Job description

Worker Type Regular Job Description Summary The Sr. Manufacturing Engineer designs and operates the manufacturing systems for AeroVironment's Unmanned Air Vehicles. In this role, the Manufacturing Engineer chooses the best technologies and processes for manufacturing, planning and designing the factory as well as managing the maintenance & continuous improvement of the manufacturing process. One has extensive knowledge in manufacturing production processes, specifically creating and monitoring automated systems and new technology development. One defines, maintains, and supports manufacturing processes utilized in the manufacture of Small Unmanned Air Vehicles.

Position Responsibilities

• Creates and manages equipment specifications, equipment documentation for development, qualification and support of assembly and test equipment for production
• Implements Lean Manufacturing principles and applies Six Sigma methodology to achieve continuous improvement in productivity, quality, and lead time
• Generates Value Stream Maps to reduce cycle time, waste, variation, and low production yields
• Creates Manufacturing Strategies and capacity models for new and current products, including estimation and maintenance of capital requisitions
• Generates new and reviews existing work instructions, assembly procedures and supporting documentation controlling the manufacturing process
• Cost estimating of new tooling and fixtures required to support production floor.
• Leads Make/Buy analysis on assemblies with cross-functional team
• Performs Design for Manufacturing, cost, and reliability analysis on new products with the design engineering team
• Works with suppliers and contract manufacturers to ensure receipt of conforming parts and assemblies
• Determines methods and procedures on new assignments and may coordinate the activities of other personnel (Team Lead)
• Other duties as assigned

Basic Qualifications (Required Skills & Experience)

• Bachelor's degree in Mechanical, Electrical or similar field is required or equivalent combination of education, training, and experience
• Minimum of 8 - 12 years of experience in Manufacturing, Mechanical, Electrical, Test Engineering or similar field in Aerospace, Automotive, or Commercial industries
• Experienced in Lean Manufacturing and Six Sigma Methodology is required
• Experienced with electro‑mechanical manufacturing, drawings, procedures and Bill of Materials is required
• Experienced using Microsoft Office (Word, Excel, Outlook, Power Point, Access, Project), MiniTab, Oracle, Agile, and CAD programs (SolidWorks is preferred)
• Occasional travel to supplier sites (up to 30%)

Other Qualifications & Desired Competencies

• Advanced degree is preferred
• Specific experience with sheet metal fabrication, plastics, composite layups, printed circuit board assembly, mechanical assembly, calibration and testing processes is desired
• Organization/planning, communication (oral and written), time management, conflict management, ability to manage stress, deadlines and work independently
• Master problem solver familiar with root cause analysis techniques
• Able to excel in a fast‑paced, deadline‑driven environment, where small teams share a broad variety of duties
• Displays strong initiative and drive to accomplish goals and meet company objectives
• Takes ownership and responsibility for current and past work products
• Is committed to learning from mistakes and driven to improve and enhance performance of oneself, others, and the company
• Demonstrates effective time management, analytical, interpersonal and communication skills
• Excels at teamwork, collaboration and putting the success of the team above one's own interests

Physical Demands

Ability to work in an office and manufacturing environment (Constant) Required to sit and stand for long periods; talk, hear, and use hands and fingers to operate a computer and telephone keyboard (Frequent)

Clearance Level

No Clearance

Salary

The salary range for this role is: $122,500 - $187,000

ITAR Requirement

ITAR Requirement: This position requires access to information that is subject to compliance with the International Traffic Arms Regulations (“ITAR”) and/or the Export Administration Regulations (“EAR”). In order to comply with the requirements of the ITAR and/or the EAR, applicants must qualify as a U.S. person under the ITAR and the EAR, or a person to be approved for an export license by the governing agency whose technology comes under its jurisdiction. Please understand that any job offer that requires approval of an export license will be conditional on AeroVironment’s determination that it will be able to obtain an export license in a time frame consistent with AeroVironment’s business requirements. A “U.S. person” according to the ITAR definition is a U.S. citizen, U.S. lawful permanent resident (green card holder), or protected individual such as a refugee or asylee. See 22 CFR § 120.15. Some positions will require current U.S. Citizenship due to contract requirements.

Benefits

AV offers an excellent benefits package including medical, dental vision, 401K with company matching, a 9/80 work schedule and a paid holiday shutdown. For more information about our company benefit offerings please visit: http://www.avinc.com/myavbenefits. We also encourage you to review our company website at http://www.avinc.com to learn more about us.

About AV:

AV isn’t for everyone. We hire the curious, the relentless, the mission-obsessed. The best of the best. We don’t just build defense technology—we redefine what’s possible. As the premier autonomous systems company in the United States, AV delivers breakthrough capabilities across air, land, sea, space, and cyber. From AI‑powered drones and loitering munitions to integrated autonomy and space resilience, our technologies shape the future of warfare and protect those who serve. Founded by legendary innovator Dr. Paul MacCready, AV has spent over 50 years pushing the boundaries of what unmanned systems can do. Our heritage includes seven platforms in the Smithsonian—but we’re not building history, we’re building what’s next. If you’re ready to build technology that matters—with speed, scale, and purpose—there’s no better place to do it than AV. We are proud to be an EEO/AA Equal Opportunity Employer, including disability/veterans. AeroVironment, Inc. is an Equal Employment Opportunity (EEO) employer and welcomes all qualified applicants. Qualified applicants will receive fair and impartial consideration without regard to race, sex, color, religion, national origin, age, disability, protected veteran status, genetic data, sexual orientation, gender identity or other legally protected status.

About AV:

AV isn’t for everyone. We hire the curious, the relentless, the mission-obsessed. The best of the best. We don’t just build defense technology—we redefine what’s possible. As the premier autonomous systems company in the United States, AV delivers breakthrough capabilities across air, land, sea, space, and cyber. From AI‑powered drones and loitering munitions to integrated autonomy and space resilience, our technologies shape the future of warfare and protect those who serve. Founded by legendary innovator Dr. Paul MacCready, AV has spent over 50 years pushing the boundaries of what unmanned systems can do. Our heritage includes seven platforms in the Smithsonian—but we’re not building history, we’re building what’s next. If you’re ready to build technology that matters—with speed, scale, and purpose—there’s no better place to do it than AV. We are proud to be an EEO/AA Equal Opportunity Employer, including disability/veterans. AeroVironment, Inc. is an Equal Employment Opportunity (EEO) employer and welcomes all qualified applicants. Qualified applicants will receive fair and impartial consideration without regard to race, sex, color, religion, national origin, age, disability, protected veteran status, genetic data, sexual orientation, gender identity or other legally protected status.