Senior Manufacturing Design Engineer: EV Propulsion

AlleyCorp; San Jose (CA); On-site; USD 127,000 - 158,000; Full time

Job summary

Archer Aviation in San Jose, CA is seeking a Sr. Manufacturing Design Engineer to bridge R&D product design and production execution for an all-electric eVTOL propulsion system. You will lead complex hardware through prototyping to mass production, owning DFM, NPI, automation specs, and MBOM development.

You will drive quality, OEE, and continuous improvement, applying Lean/Six Sigma methods and advanced CAD/PLM/MES/ERP tooling. A highly regulated, fast-paced environment awaits.

Qualifications

• Bachelor’s degree in Mechanical, Manufacturing, or Electrical Engineering with 3–6+ years hands‑on experience.
• Hands‑on assembly experience with advanced automated manufacturing equipment.
• Proficiency in Statistical Process Control (SPC), Geometric Dimensioning and Tolerancing (GD&T), and drawing reviews.
• End-to-end NPI execution from prototyping to high‑volume mass production.
• Structured problem solving using Lean, Six Sigma, DMAIC, 8D, 5-Why.
• Proficiency with CAD (NX, AutoCAD), PLM, MES, and ERP systems.
• Strong communication skills in a fast-paced, regulated environment.

Responsibilities

• Design for Manufacturability: spearhead DFM/DFA initiatives with cross-functional teams to optimize EPS manufacturability.
• NPI & Prototype Execution: lead prototype builds, process trials, tooling, and ramp-up.
• Automation & Tooling Specs: define specs for automation equipment, tools, fixtures, and vendor FAT/SAT.
• Line Design & MBOM Development: develop plant layouts, part flow, methods, MBOM.
• Quality & Process Control: conduct PFMEAs, validation/calibration protocols, standardized work.
• OEE & Continuous Improvement: monitor pilot line performance, RCCA, optimize cycle times.

Skills

DFM

NPI

Automation

MBOM

Quality control

OEE

CAD/PLM/MES/ERP

Lean Six Sigma

Communication

Education

Bachelor’s degree in Mechanical/Manufacturing/Electrical Engineering

Tools

NX

AutoCAD

PLM

MES

ERP

Job description

Archer Aviation in San Jose, CA is seeking a Sr. Manufacturing Design Engineer to bridge R&D product design and production execution for an all-electric eVTOL propulsion system. You will lead complex hardware through prototyping to mass production, owning DFM, NPI, automation specs, and MBOM development.

You will drive quality, OEE, and continuous improvement, applying Lean/Six Sigma methods and advanced CAD/PLM/MES/ERP tooling. A highly regulated, fast-paced environment awaits.