Manufacturing Process Flow & Control DFX Engineer III (Subsystem)

Blue Origin LLC; San Francisco (CA); On-site; USD 121,000 - 169,000; Full time

Benefits offered by this job

Medical insurance

401(k) match

Paid time off

Job summary

Blue Origin is seeking a Manufacturing Process Flow & Control DFX Engineer to own the architecture and end-to-end control of our production lines from raw material entry to final delivery. You will connect manufacturing cells, define CPPs/CQAs, and lead DFM, DFA and DFT reviews to optimize flow and verification across the line.

This cross-functional role partners with Manufacturing, Quality and Automation to implement SPC and MES workflows, drive first-pass yield, and ensure traceability and

Qualifications

• Bachelor's degree in Mechanical, Aerospace, Industrial or Manufacturing Engineering or related field.
• 5+ years in manufacturing engineering, production systems, or process engineering in high-complexity environments.
• Experience designing or improving end-to-end manufacturing flows with multiple steps.
• Knowledge of PFMEA, SPC, CPK, and other process control methods.
• Experience defining verification and test strategies within production.

Responsibilities

• Design and own end-to-end manufacturing flow, connecting cells to form a complete production line.
• Develop and maintain Value Stream Maps and Process Flow Diagrams for the full production system.
• Lead DFM, DFA, DFT reviews to optimize flow and control.
• Define line-level process control strategies, CPPs, and CQAs across all cells.
• Drive SPC, MES workflows, line health analytics, and first-pass yield improvements.

Skills

End-to-end flow design

Lean manufacturing

SPC (Statistical Process Control)

DFM (Design for Manufacturability)

DFT (Design for Testability)

Cross-functional collaboration

Data-driven decisions

Education

Bachelor's in Engineering

Tools

Solumina

SAP ME

Sight Machine

Siemens Plant Simulation

Job description

Application close date:Applications will be accepted on an ongoing basis until the requisition is closed.At Blue Origin, we envision millions of people living and working in space for the benefit of Earth. We’re working to develop reusable, safe, and low-cost space vehicles and systems within a culture of safety, collaboration, and inclusion. Join our team of problem solvers as we add new chapters to the history of spaceflight!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.At Blue Origin, we believe in the power of manufacturing excellence to make space accessible and to benefit Earth. We are seeking a talented Manufacturing Process Flow & Control DFX Engineer to join our team and own the architecture, integration, and end-to-end control of our manufacturing lines. You will serve as the critical link between individual manufacturing cells, ensuring seamless flow, traceability, and verification across the entire production system — from raw material entry to final product delivery.This is a uniquely cross-functional role requiring both a systems-thinking mindset and deep manufacturing engineering expertise. You will influence how rockets and spacecraft are built, ensuring every process step is intentional, controlled, measurable, and verified.What You'll DoManufacturing Line Architecture & Flow DesignDesign and own the end-to-end manufacturing process flow, defining how individual manufacturing cells are physically and logically connected to form a complete production lineDevelop and maintain Value Stream Maps (VSMs) and Process Flow Diagrams (PFDs) that represent the full material and information flow across the production systemEstablish manufacturing cell interfaces — defining inputs, outputs, handoff criteria, and interdependencies between cellsLead Design for Manufacturability (DFM), Design for Assembly (DFA), and Design for Testability (DFT) reviews to ensure products and processes are optimized for flow and controlIdentify and eliminate bottlenecks, waste, and flow disruptions using Lean manufacturing principles and systematic analysisEnd-to-End Process ControlDefine and implement process control strategies at the line level, ensuring that critical process parameters (CPPs) and critical quality attributes (CQAs) are monitored and controlled across all cellsDevelop Control Plans and Process Control Documents (PCDs) that span the entire manufacturing line, not just individual operationsEstablish inter-cell control gates — defining hold/release criteria that must be satisfied before work-in-progress (WIP) moves between manufacturing cellsPartner with Manufacturing Engineering, Quality, and Automation teams to implement Statistical Process Control (SPC) and real-time monitoring solutions at the line levelDrive first-pass yield improvement and escape prevention through proactive process control strategiesVerification & Test Integration (End-to-End)Define the test coverage matrix, mapping product requirements and process risks to specific test and inspection points throughout the production flowPartner with Test Engineering to design in-process verification stations, functional test sequences, and acceptance test procedures (ATPs) that are integrated into the line flowEnsure test data traceability — all test results, process data, and verification records are captured, linked to serialized hardware, and accessible for downstream decision-makingLead the development of Go/No-Go criteria and accept/reject disposition workflows at each verification gate within the lineDrive DFT (Design for Testability) initiatives with product design teams to improve test access, observability, and controllabilityDigital Thread & Data ArchitecturePartner with Manufacturing IT and Digital Engineering teams to implement Manufacturing Execution System (MES) workflows that enforce process sequencing, capture verification data, and flag non-conformancesEnsure end-to-end serialization and traceability of hardware, materials, and process records from first operation to final acceptanceLeverage manufacturing data to perform line health analytics, identifying systemic issues before they result in escapes or delivery impactsDFX Leadership & Design PartnershipEngage with product design teams early in the development lifecycle to influence design decisions through the lens of manufacturability, flow efficiency, and testabilityLead formal DFX reviews (DFM, DFA, DFT, DFI, DFC) at key program milestones (PDR, CDR, PRR, MRR)Identify design features that create flow disruptions, rework loops, or untestable conditions, and drive design changes to resolutionChampion the use of digital twins and virtual factory simulations to model and validate line flow prior to physical implementationContinuous Improvement & Line ReadinessDrive continuous improvement initiatives targeting line throughput, flow efficiency, first-pass yield, and test cycle timeDevelop and maintain line performance dashboards tracking key metrics: takt adherence, WIP levels, yield by cell, test pass rates, and escape metricsSupport root cause analysis (RCA) and corrective action for systemic line-level issuesMinimum QualificationsBachelor's degree in Mechanical Engineering, Aerospace Engineering, Industrial Engineering, Manufacturing Engineering, or a related technical field5+ years of experience in manufacturing engineering, production systems, or process engineering in an aerospace, defense, automotive, or high-complexity manufacturing environmentDemonstrated experience designing or improving end-to-end manufacturing flows with multiple interconnected process stepsWorking knowledge of process control methodologies — Control Plans, PFMEA, SPC, CPK analysisExperience defining or implementing verification and test strategies within a production environmentStrong understanding of Lean Manufacturing principles — flow, pull, takt, waste elimination, value stream mappingProven ability to work cross-functionally across engineering, quality, operations, and supply chainStrong analytical and problem-solving skills with a data-driven approach to decision-makingPreferred QualificationsMaster's degree in Engineering or Manufacturing SystemsExperience with propulsion systems, structures, avionics, or fluid systemsmanufacturingHands-on experience with MES platforms (e.g., Solumina, SAP ME, Sight Machine, or similar)Familiarity with digital twin or simulation tools for manufacturing (e.g., Siemens Plant Simulation, Arena, or similar)Experience with automated test systems and functional test development for complex hardwareKnowledge of AS9100, AS9102 (FAI), and NASA/DoD manufacturing standardsLean Six Sigma Green Belt or Black Belt certificationExperience in a high-mix, low-volume manufacturing environment with serialized hardware traceability requirementsFamiliarity with Model-Based Definition (MBD) and Model-Based Enterprise (MBE) environmentsWhat You'll BringA systems thinker who sees the entire manufacturing line as an integrated system, not a series of isolated operationsDeep passion for building discipline into manufacturing — ensuring that every control, verification, and handoff is purposeful and rigorousComfort operating in ambiguous, fast-paced environments where you will help define the processes before they fully existA collaborative spirit with the ability to influence without authority across engineering and operations teamsAn uncompromising commitment to safety and quality in everything you doBase Pay Range for:CA applicants is $121,023.00 - $169,432.20Other site ranges may differCulture StatementDon’t meet all desired requirements? Studies have shown that some people are less likely to apply to jobs unless they meet every single desired qualification. At Blue Origin, we are dedicated to building an authentic workplace, so if you’re excited about this role but your past experience doesn’t align perfectly with every desired qualification in the job description, we encourage you to apply anyway. You may be just the right candidate for this or other roles.Export Control RegulationsApplicants for employment at Blue Origin must be a U.S. citizen or national, U.S. permanent resident (i.e. current Green Card holder), or lawfully admitted into the U.S. as a refugee or granted asylum.Background CheckRequired for all positions: Blue’s Standard Background CheckRequired for Certain Job Profiles: Defense Biometric Identification System (DBIDS) background check if at any time the role requires one to be on a military installationRequired for Certain Job Profiles: Drivers who operate Commercial Motor Vehicles with a Gross Vehicle Weight (GVW), Gross Vehicle Weight Rating (GVWR) or combination of power unit and trailer that meets or exceeds 10,001 lbs. and/or transports placardable amounts of hazardous materials by ground in any vehicle on a public road while in commerce, may be subject to additional Federal Motor Carrier Safety Regulations including: Driver Qualification Files, Medical Certification (obtained before onboarding), Road Test, Hours of Service, Drug and Alcohol Testing, vehicle inspection requirements, CDL requirements (if applicable) and hazardous materials transportation/shipping training.Required for certain Job Profiles: Ability to obtain and maintain Merchant Mariner Credential, which includes pre-employment and random drug testing as well as DOT physicalBenefitsBenefits 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.Equal Employment OpportunityBlue Origin is proud to be an Equal Opportunity/Affirmative Action Employer and is committed to attracting, retaining, and developing a highly qualified and dedicated work force. Blue Origin hires and promotes people on the basis of their qualifications, performance, and abilities. We support the establishment and maintenance of a workplace that fosters trust, equality, and teamwork. We provide all qualified applicants for employment and employees with equal opportunities for hire, promotion, and other terms and conditions of employment, regardless of their race, color, religion, sex, sexual orientation, gender identity, national origin/ethnicity, age, physical or mental disability, genetic factors, military/veteran status, or any other status or characteristic protected by federal, state, and/or local law. Blue Origin will consider for employment qualified applicants with criminal histories in a manner consistent with applicable federal, state, and local laws, including the Washington Fair Chance Act, the California Fair Chance Act, the Los Angeles Fair Chance in Hiring Ordinance, and other applicable laws.Affirmative Action and Disability AccommodationApplicants wishing to receive information on Blue Origin’s Affirmative Action Plans, or applicants requiring a reasonable accommodation in order to participate in the application and/or interview process, please contact us at [e-mail] . Please note this is a publicly managed inbox. Please do not include any personal medical information in your request.