Senior Electrical Manufacturing Engineer

PDW; Huntsville (AL); On-site; USD 85,000 - 110,000; Full time

Benefits offered by this job

Comprehensive BCBS medical coverage

401(K) with company match

Paid Parental Leave

On-site gym

Job summary

Performance Drone Works (PDW) in Huntsville, AL is seeking a Senior Electrical Manufacturing Engineer to enhance manufacturability and production readiness across multiple systems. Responsibilities include optimizing assembly processes, leading NPI efforts, and driving continuous improvement initiatives. Candidates should have a B.S. in Electrical Engineering and over 10 years of relevant experience. Benefits include comprehensive health coverage, a 401(K) plan, and flexible leave options.

Qualifications

• 10+ years’ experience supporting NPI and sustaining electrical manufacturing.
• Experience leading DFM/DFT and PFMEA efforts.
• Experience in defining automation equipment requirements.

Responsibilities

• Drive manufacturability and production readiness across sUAS platforms.
• Optimize electrical manufacturing and test processes.
• Conduct root cause analysis and corrective actions.

Skills

DFM/DFT expertise

NPI experience

High-volume manufacturing knowledge

Automation understanding

Excel/data analysis skills

Education

B.S. in Electrical Engineering

Tools

Visio

AutoCAD

Altium

Minitab

Job description

Performance Drone Works (PDW) builds technologies for the warfighter, by the warfighter. Born out of the Drone Racing League, our roots are competitive, our mindset is tactical, and our mission is clear: deliver purpose-built unmanned systems to those who serve. We are not here to sell vapor; we build and ship real capabilities for real missions.

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 and maintain a U.S. Secret security clearance or higher, as required.

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.

Work Environment

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 work hours for this position 7:00 a.m. to 3:30 p.m. with occasional overtime as operational needs demand.

Benefits

• Comprehensive BCBS medical, dental, and vision coverage; 80% sponsored by the company.
• Safe Harbor 401(K) with company match.
• Paid Parental Leave.
• A work environment that encourages teamwork and innovation.
• On‑site gym at our Huntsville, AL location.
• 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.