Senior Manufacturing/Process Engineer (Prometheus Energetics)

Kratos Defense & Security Solutions, Inc.; Bloomington (IN); On-site; USD 120,000 - 150,000; Full time

Job summary

Prometheus Energetics, a Kratos Defense & Security Solutions JV, seeks a Senior Manufacturing & Process Engineer in Bloomington, IN to guide startup-to-high-rate production of energetic components. You will own processes, SWIs, line layouts, and tooling integration, interfacing with Engineering, Operations, Quality, and EHS to meet safety and performance goals.

You will leverage 6+ years in aerospace/defense manufacturing, CAD tooling, PFMEAs, and Lean Six Sigma to drive continuous improvement,

Qualifications

• Bachelor’s degree in Mechanical, Aerospace, Manufacturing or related field.
• Minimum of 6+ years in manufacturing, process, or tooling engineering in aerospace/defense.
• Proficiency in 3D CAD and PLM systems; strong GD&T and precision fabrication fundamentals.
• Experience creating routers, PFMEAs, process flows, and work instructions.
• Excellent written and verbal communication; US citizenship capable of obtaining clearance.

Responsibilities

• Establish and sustain manufacturing processes, SWIs, routers, and tooling for SRM cast/cure and assembly.
• Analyze flows, ergonomics, and line balance to improve throughput and scale production.
• Serve as primary engineering contact on shop floors, providing troubleshooting and direction.
• Define and integrate tooling, fixtures, and capital equipment with vendors and internal teams.
• Lead RCCA investigations, DR/SPE improvements, and ensure compliance with safety standards.

Skills

Manufacturing Engineering

Process Engineering

3D CAD

GD&T

PFMEA

Lean/Six Sigma

Education

BA/BS

Tools

PTC Creo

Siemens NX

SolidWorks

Windchill

Job description

Senior Manufacturing/Process Engineer (Prometheus Energetics)

• Job Tracking ID : 85347-369586
• Job Location : Bloomington, IN
• Job Level : Mid Career (2+ years)
• Level of Education : BA/BS
• Job Type : Full-Time/Regular
• Date Updated : 07/25/2026
• Years of Experience : 6+ Years
• Starting Date : Invalid Date
• Travel Requirement :
• Compensation :
• Capabilities :
• Salary : $0
• Years Of Experience : 6+

Job Description

About Prometheus Energetics

Prometheus Energetics is an independent U.S.-based merchant supplier of solid rocket motors and warheads. A joint venture between Kratos Defense & Security Solutions and Rafael Advanced Defense Systems, Prometheus combines U.S. industrial speed and credibility with decades of combat-proven designs, manufacturing know-how, and technical training to deliver field-ready products at scale.

Position Summary

Prometheus Energetics is seeking an experienced Senior Manufacturing & Process Engineer to serve as a critical technical authority as our Bloomington operations transition from facility startup and product industrialization into high-rate production.

In this role, you will bridge product design and shop-floor execution. You will own the manufacturing processes, standard work instructions, production line layouts, and specialized energetic tooling integration required to build tactical solid rocket motors and warheads safely and efficiently. Working closely with Engineering, Operations, Quality, EHS, and strategic partner technology-transfer teams, you will ensure that energetic mixing, casting, curing, machining, and final assembly operations satisfy all technical, quality, safety, and customer performance requirements.

Key Responsibilities

Process Engineering & Shop Floor Integration

• Establish, prove out, and sustain manufacturing processes, operational routers, tooling sheets, and detailed Standard Work Instructions (SWIs) for solid rocket motor (SRM) cast/cure, propellant handling, motor assembly, and energetic packaging operations.
• Analyze operational flows, workstation ergonomics, and line balance to optimize throughput, reduce cycle times, and support rapid production scaling.
• Serve as the primary manufacturing engineering contact for shop-floor operators and technicians, providing real-time troubleshooting, guidance, and technical direction on active production lines.

Tooling Architecture & Capital Equipment

• Partner with Tooling Engineers to translate product design requirements and energetic process constraints into robust, safe, and reliable production tooling, molds, fixtures, holding C-frames, and rotation carts.
• Define capital equipment specifications, evaluate vendor technical proposals, and manage full-lifecycle acquisition and integration of specialized manufacturing machinery.
• Lead on-site equipment installation, proof loading, line buy-off, and operational validation prior to releasing equipment into active energetic production.

Non-Conformance, MRB & Continuous Improvement

• Act as an active voting member on the Material Review Board (MRB) to evaluate non-conforming hardware, perform engineering dispositions, and implement containment protocols.
• Lead formal Root Cause Corrective Action (RCCA) investigations for hardware non-conformances, process escapes, and tooling wear using 5-Why, Fishbone, and 8D methodologies.
• Drive continuous improvement and high first-pass yield using Lean/Six Sigma practices, Process Failure Mode and Effects Analysis (PFMEA), Statistical Process Control (SPC), and mistake-proofing (poka-yoke) controls.

Explosive Safety, ESD & Compliance

• Partner with Environmental Health & Safety (EHS) and Energetics Safety teams to strictly enforce site-specific explosive safety standards (e.g., DoD 4145.26-M), Electrostatic Discharge (ESD) controls, and OSHA guidelines across all equipment and processes.
• Ensure full compliance with AS9100 quality standards, Nadcap requirements, customer drawing specifications, and federal ammunition and explosives regulations.

Performance Management

Establish actionable dashboards, review tooling performance with engineering and operational leadership, and hold owners accountable for recovery and improvement plans. Measures may include:

• Process design-to-release schedule compliance and milestone execution
• Vendor quality, delivery performance, and technical drawing compliance for equipment and tooling
• Process-and tooling-related scrap, rework, cost of poor quality, and first-pass yield impact
• Root-cause investigation aging, recurrence prevention, and RCCA effectiveness
• Equipment proof-load, calibration, and maintenance plan compliance
• Explosive safety, ESD, and ergonomic compliance across all active processing assets
• Manufacturing team capability, technical development, and program support effectiveness

Experience and Skills

Required Qualifications

• Bachelor’s degree in Mechanical Engineering, Aerospace Engineering, Manufacturing Engineering, or a related technical discipline.
• Minimum of 6+ years of progressive manufacturing, process, or tooling engineering experience in an aerospace and defense hardware manufacturing environment.
• Proficiency in 3D CAD software (e.g., PTC Creo, Siemens NX, SolidWorks) and Product Data Management (PDM/PLM) systems (e.g., Windchill).
• Solid understanding of Geometric Dimensioning and Tolerancing (GD&T per ASME Y14.5), structural strength of materials, and precision metal fabrication methods.
• Proven experience generating assembly routers, process flow diagrams, PFMEAs, and detailed work instructions from complex engineering drawing packages.
• Excellent written, verbal, analytical, and executive communication skills.
• U.S. citizenship and the ability to obtain and maintain a U.S. Government Secret Security Clearance.

Preferred Qualifications

• Master of Science in Mechanical Engineering, Aerospace Engineering, or Engineering Management.
• Direct experience in solid rocket motor manufacturing, propellant casting/curing, warheads, pyrotechnics, ammunition, or high-hazard chemical/energetic processing.
• Hands-on familiarity with press tooling, hydraulic/pneumatic actuation systems, automated handling carts, and optical/CMM metrology systems.
• ASQ certifications (CQE, CQA), formal GD&T certification, or Six Sigma Green/Black Belt credentials.
• Prior experience standing up manufacturing lines or integrating new production facilities in a startup or rapid defense expansion environment.
• Active U.S. Secret Security Clearance or higher.

Job Benefits

• Medical, Dental & Vision Insurance Coverage
• Life/ADD & Short/Long Term Disability Insurance
• 401(k) Savings Plan
• Employee Stock Purchase Plan (ESPP)
• Paid Time-Off (PTO)
• Holidays
• Education Reimbursement

Kratos Defense is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race,color, religion, sex, sexual orientation, gender identity, national origin, age, pregnancy, genetic information, disability, status as aprotected veteran, or any other protected category under applicable federal, state, and local laws.

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