Senior Electrical Manufacturing Engineer

Performance Drone Works, LLC; Huntsville (AL); On-site; USD 120,000 - 180,000; Full time

Benefits offered by this job

On-site gym facilities at Huntsville

Job summary

Performance Drone Works in Huntsville, AL seeks a Senior Electrical Manufacturing Engineer to drive manufacturability, production readiness, and scalable factory design across multiple sUAS platforms. You will collaborate with Design Engineering, Quality, and Supply Chain to enable high-volume production with built-in quality and safe, repeatable builds.

This role requires 10+ years in electrical manufacturing, strong DFM/DFT and PFMEA experience, and the ability to design automation-ready

Qualifications

• B.S. in Electrical Engineering with 10+ years' NPI and sustaining electrical manufacturing experience.
• Proven success leading DFM/DFT and PFMEA across cross-functional teams.
• Experience designing and scaling automated or semi-automated assembly and test lines for high-volume production.
• Eligible for U.S. Secret security clearance or higher.

Responsibilities

• Collaborate with Design Engineering to provide DFM/DFT input from concept through release; deliver inputs to improve manufacturability, assembly, testability, and cost for high-volume production.
• Lead optimization of electrical manufacturing, assembly, and test processes for new and existing products (avionics, power distribution, RF components, embedded systems, PCBAs, motors, controllers, cables).
• Develop, validate, release, and continuously improve manufacturing documentation (work instructions, process flows, routings, control plans, test procedures).
• Troubleshoot production/test issues; perform RCA and implement CAPA to improve safety, quality, delivery, and cost.
• Support development, validation, and sustainment of electrical test systems and fixtures to meet performance and OEE requirements.
• Collaborate with Quality, Supply Chain, and suppliers on product qualification, component availability, and inspection/test strategies (PFMEA, control plans).
• Establish labor standards and staffing models using time studies; align standard work to takt time and production targets.
• Develop capacity models for resources; identify bottlenecks and drive mitigation plans.
• Design and optimize factory layouts (line/cell) including material flow, kitting, WIP, and ergonomics.
• Identify automation opportunities; support line readiness, tooling, training, and ramp of automation.
• Define and validate production tooling, fixturing, and gaging for safe, repeatable builds.
• Partner with NPI to plan prototype, pilot, and ramp builds; drive line readiness and learnings.
• Drive continuous improvement (5S, Kaizen, Kanban, SMED, line balancing) to reduce waste and improve first-pass yield.
• Support cost/investment decisions; contribute to make/buy analyses and capital justifications.

Skills

DFM/DFMA

PFMEA

NPI/industrialization

Automation

CAPA

Line balancing

Excel/Data analysis

Visio/AutoCAD

Education

B.S. in Electrical Engineering

Tools

Altium

Visio

AutoCAD

PLC/HMI

LabVIEW

Minitab

Power BI

Job description

Senior Electrical Manufacturing Engineer

Performance Drone Works (PDW) is building the next generation of tactical robotic systems used across defense, national security, and public safety missions. We are building a new center of engineering excellence to design our new category of tactical robotic systems and the industrial capacity to deliver them, bringing decisive airpower into the hands of every operator. We are not here to make promises; we are here to deliver real systems with real capabilities for real missions.

You will join a team of operators, engineers, and builders who solve hard problems with humility and focus. We design and produce multi-mission aerial systems that operators trust to perform in real-world conditions, reliably, repeatedly, and at scale. Our approach is grounded in operator-centered design, rapid iteration from field use, and U.S.-based manufacturing. Weoperateby a clear set of values: Mission First, Aim Farther, Own It, Win Together. This is how we build advantage and how we help protect our service members, our communities, and our country.

Now, we’re entering a new phase of growth and are looking for a Senior Electrical Manufacturing Engineer to drive manufacturability, production readiness, and scalable factory design across multiple sUAS platforms. This role partners with Design Engineering, Quality, Supply Chain, and Operations to lead DFM/DFMA, NPI industrialization, tooling and fixturing, built-in quality, capacity modeling, automation readiness for high-volume production, and factory/line layout optimization to improve throughput, cost, quality, and safety.

What You’ll Do

• Collaborate with Design Engineering to provide DFM/DFT input from concept through release; deliver clear, prioritized inputs to improve electrical designs for manufacturability, assembly, testability, and cost for high-volume production.
• Lead optimization of electrical manufacturing, assembly, and test processes for new and existing products (e.g., avionics, power distribution, RF components, embedded systems, PCBAs, motors, controllers, cable harnesses).
• Develop, validate, release, and continuously improve manufacturing documentation, including work instructions, process flows, routings, control plans, and test procedures.
• Troubleshoot production and test issues across assemblies and systems; perform root cause analysis (RCA) and implement corrective and preventive actions (CAPA) to improve safety, quality, delivery, and cost.
• Support development, validation, and sustainment of electrical test systems and fixtures to meet performance and OEE requirements.
• Collaborate with Quality, Supply Chain, and suppliers to support product qualification, component availability, and inspection/test strategies (including PFMEA and control plans).
• Establish labor standards and staffing models using time studies (e.g., stopwatch, MOST/MTM); align standard work to takt time and production targets.
• Develop capacity models for critical resources (labor, equipment, test stations), identify bottlenecks, and drive mitigation plans.
• Design and optimize factory layouts (line/cell), including material flow, kitting, point-of-use storage, WIP control, and ergonomic/safety considerations.
• Identify, evaluate, and industrialize automation opportunities for high-volume assembly and test; support specification, layout, commissioning, and ramp-up of semi- and fully automated workcells and lines.
• Define and validate production tooling, fixturing, and gaging (e.g., assembly jigs, test fixtures, torque tools, poka-yoke devices) to enable safe, repeatable, and efficient builds.
• Partner with NPI to plan and execute prototype, pilot, and ramp builds, including line readiness, tooling, training, and build learning capture.
• Drive continuous improvement initiatives (e.g., 5S, Kaizen, Kanban, SMED, line balancing) to reduce waste, improve throughput, and increase first-pass yield through built-in quality and error-proofing.
• Support cost and investment decisions by quantifying labor, equipment, and space requirements; contribute to make/buy analyses and capital justifications.

Requirements

• B.S. in Electrical Engineering, or related engineering discipline with 10+ years’ experience directly supporting NPI and sustaining electrical manufacturing; aerospace/defense and high-mix electromechanical assembly preferred.
• Demonstrated success leading DFM/DFT and PFMEA cross-functional design-to-manufacturing efforts.
• Strong NPI/industrialization experience (prototype/pilot/ramp/sustainment) including line readiness, documentation, ramp, and continuous improvement.
• Experience supporting high-volume, high-throughput manufacturing, including designing and scaling automated or semi-automated assembly and test lines.
• Demonstrated experience defining automation equipment requirements specifications and acceptance criteria (URS), supporting capital justifications, and participating in FAT/SAT, process validation, and production ramp to rate.
• Working familiarity with automation technologies and metrics (robotics/cobots, vision systems, automated torque/dispense, conveyors, PLC/HMI concepts, OEE and downtime analysis).
• Hands-on experience defining requirements for manufacturing tooling, fixtures, and gages; coordinating design/fabrication, acceptance testing, and release into production.
• Working knowledge of built-in quality methods (quality at the source, poka-yoke, control plans, PFMEA, gage R&R, and in-process checks) and partnering with Quality to drive capability and reduce escapes.
• Proven capability in capacity planning, line balancing, labor standards, and time studies; advanced Excel/data analysis skills required (e.g.: Minitab, LabView, MS Power BI a plus).
• Proficiency with layout and visualization (Visio, AutoCAD) and CAD tools (Altium) and generating ECOs using PLM (Duro) applying ergonomic and safety principles.
• Familiarity with ERP/MES master data and manufacturing documentation (BOMs, routings, work centers, revisions); Lean/Six Sigma experience and strong communication skills.
• Must be eligible to obtain andmaintaina U.S. Secret security clearance or higher, asrequired.

Physical Requirements

The physical demands described here are representative of those that must be met to successfully perform the essential functions of the job. Ability to sit, stand, bend, reach, climb, and move about regularly throughout the day and lift / carry up to 25 pounds. Must have manual dexterity to operate standard office equipment.

This position typically operates in a standard office setting and manufacturing environment. This role requires use of standard office equipment and may involve exposure to equipment, tools, machinery, hazardous chemicals, or materials relevant to the role. This position may have exposure to outdoor weather conditions, noise, and non-climate-controlled environments. May require the use of personal protective equipment (PPE) depending on the environment. This is a fast-paced work environment and requires cross departmental collaboration with independent and team-based responsibilities. Standard works hours for this position 7:00 a.m. to 3:30 p.m. with occasional overtime as operational needs demand.

PDW values our team, and we offer a compensation package reflective of your experience and capabilities. Benefits include:

• Comprehensive BCBS medical, dental, and vision coverage; 80% sponsored by the company.
• Safe Harbor 401(K) with company match.
• A work environment that encourages teamwork and innovation.
• On-site gym at our Huntsville, AL and Denver, CO locations.
• Employer provided life insurance.
• Robust Employee Assistant Program (EAP).
• Competitive salary, generous paid time off (PTO), and flexible leave options.

EEO Statement

PDW is an equal opportunity employer that upholds all federal and state non-discrimination laws. We ensure a fair and unbiased evaluation for employment for all qualified candidates regardless of race, color, religion, age, sex, sexual orientation, gender identity, national origin, marital status, medical condition, disability, genetic information, veteran status, or any other characteristic protected by law.