Senior Process Engineer Facilities
Avio Usa Inc
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Benefits offered by this job
Job summary
Avio USA is seeking a Senior Process & Facilities Engineer to lead the development, buildout, commissioning, and launch of a new aerospace manufacturing facility in Hurt, Virginia. You will translate production requirements into facility layouts and equipment needs, collaborating across engineering, operations, facilities, and program leadership.
The ideal candidate has hands-on experience in manufacturing process and facilities engineering, capital projects, and production ramp, with aerospace
Qualifications
- Bachelor's degree in Mechanical, Manufacturing, Industrial, Chemical, or Materials engineering.
- 7+ years of progressive experience in manufacturing engineering, process engineering, facilities engineering, or capital projects.
- Experience with manufacturing facility development, production equipment, or major facility/capital projects.
- Experience developing manufacturing-area layouts and optimizing production flow.
- Experience managing or supporting capital projects involving equipment installation and facility modifications.
- Experience developing engineering specifications, scopes of work, operating procedures, and technical documentation.
- Demonstrated ability to work directly with contractors, equipment suppliers, manufacturing personnel, and cross‑functional engineering teams.
- Strong mechanical aptitude and practical understanding of manufacturing equipment and industrial systems.
- Ability to manage multiple projects while maintaining cost, schedule, safety, and technical requirements.
Responsibilities
- Specify, design, procure, install, and commission process equipment for energetic and inert operations.
- Coordinate equipment installation and integration with facility infrastructure.
- Develop equipment acceptance criteria and commissioning plans.
- Troubleshoot equipment and process issues during startup and production ramp.
- Improve facility and manufacturing-area layouts that optimize production flow, material movement, equipment utilization, safety, quality, and future expansion.
- Inform requirements for utilities and facility systems supporting manufacturing equipment
- Identify facility constraints and design conflicts and drive resolution with internal and external engineering teams.
- Support site construction, facility modifications, equipment installation, and production-area readiness.
- Production Launch & Ramp: Develop and execute equipment and process commissioning plans.
- Production Launch & Ramp: Support pilot builds, first production runs, process qualification, and production-rate increases.
- Production Launch & Ramp: Identify and resolve process, equipment, facility, and material-flow constraints.
- Production Launch & Ramp: Establish production metrics and use data to drive continuous improvement.
- Production Launch & Ramp: Partner with Operations to transition engineering-developed processes into stable production.
- Production Launch & Ramp: Support development of future capacity and factory expansion plans.
- Process Safety & Aerospace/Defense Compliance: Ensure safety and hazard controls in designs.
- Process Safety & Aerospace/Defense Compliance: Participate in hazard analyses and safety reviews.
- Process Safety & Aerospace/Defense Compliance: Ensure compliance with security, export control, and regulatory requirements.
Skills
Education
Tools
Job description
401(k)
Employee discounts
Health insurance
Paid time off
401(k) matching
Bonus based on performance
Competitive salary
Dental insurance
Opportunity for advancement
Relocation bonus
Vision insurance
Location: Hurt, Virginia Department: Operations Reports To: Chief Operating Officer
Avio USA is seeking a Senior Process & Facilities Engineer to play a key role in the development, buildout, commissioning, and launch of a new aerospace and defense manufacturing facility to be located in Hurt, Virginia. This position will be responsible for translating manufacturing processes and production requirements into facility layouts, equipment requirements and selection, production flow, and operational processes. The engineer will work across engineering, operations, facilities, quality, safety, security, contractors, equipment suppliers, and program leadership to take the factory from design through installation, commissioning, qualification, and production ramp.
The ideal candidate is a hands‑on engineer with significant experience in manufacturing process engineering, facilities engineering, capital projects, production equipment, and factory startup. Experience in aerospace, defense, propulsion, energetics, composites, advanced materials, or other complex manufacturing environments is strongly preferred.
This is not a traditional process‑improvement role. The successful candidate will be expected to help build the manufacturing environment itself.
Specify, design, procure, install, and commission process equipment for energetic and inert operations.
Work with process equipment design firms and equipment manufacturers and integrators to resolve arrive at the correct process equipment solution.
Coordinate equipment installation and integration with facility infrastructure.
Develop equipment acceptance criteria and commissioning plans.
Troubleshoot equipment and process issues during startup and production ramp.
Support equipment upgrades, modifications, preventive maintenance improvements, and reliability initiatives.
Review architectural, mechanical, electrical, plumbing, and equipment drawings for alignment with manufacturing and process equipment requirements.
Improve facility and manufacturing‑area layouts that optimize production flow, material movement, equipment utilization, safety, quality, and future expansion.
Inform requirements for utilities and facility systems supporting manufacturing equipment
Identify facility constraints and design conflicts and drive resolution with internal and external engineering teams.
Support site construction, facility modifications, equipment installation, and production‑area readiness.
Support production readiness activities from initial equipment installation through sustained production.
Develop and execute equipment and process commissioning plans.
Support pilot builds, first production runs, process qualification, and production‑rate increases.
Identify and resolve process, equipment, facility, and material‑flow constraints affecting production.
Establish production metrics and use data to drive continuous improvement.
Partner with Operations to transition engineering‑developed processes into stable production.
Support development of future capacity and factory expansion plans.
Incorporate appropriate safety and hazard controls into facility, equipment, and process designs.
Participate in process hazard analyses, equipment hazard assessments, and safety reviews.
Work closely with EHS, Quality, Security, and Operations to ensure facilities and processes meet applicable requirements.
Develop and maintain controlled engineering and manufacturing documentation.
Support process and facility qualification activities.
Participate in internal, customer, regulatory, and government reviews as applicable.
Ensure appropriate consideration of security, export control, configuration management, quality, environmental, and safety requirements in facility and process development.
Bachelor's degree in Mechanical, Manufacturing, Industrial, Chemical, Materials, or related engineering discipline.
7+ years of progressive experience in manufacturing engineering, process engineering, facilities engineering, or capital project engineering.
Demonstrated experience with manufacturing facility development, production equipment, or major facility/capital projects.
Experience developing manufacturing‑area layouts and optimizing production flow.
Experience managing or supporting capital projects involving equipment installation and facility modifications.
Experience developing engineering specifications, scopes of work, operating procedures, and technical documentation.
Demonstrated ability to work directly with contractors, equipment suppliers, manufacturing personnel, and cross‑functional engineering teams.
Strong mechanical aptitude and practical understanding of manufacturing equipment and industrial systems.
Ability to manage multiple projects while maintaining cost, schedule, safety, and technical requirements.
Aerospace and defense manufacturing experience.
Experience with rocket motors, energetics, propellants, composites, advanced materials, or other hazardous or regulated manufacturing processes.
Experience with greenfield manufacturing facility development or major facility expansion.
Experience with HVAC/dehumidification systems and industrial process utilities.
Experience with mixing, casting, curing, machining, molding, coating, chemical processing, or similar manufacturing processes.
Experience with automated manufacturing cells, robotics, CNC machining, vision inspection, or industrial controls.
Six Sigma or Lean Manufacturing certification.
Experience performing or participating in process hazard analysis and safety reviews.
Experience with CAD and 3D modeling tools.
Experience managing capital projects with budgets of $1M+.
Experience supervising contractors during construction or equipment installation.
Active U.S. security clearance or prior experience working in a cleared environment.
This position may involve access to U.S. Government‑controlled information, export‑controlled technical data, controlled equipment, or secure facilities.
Where required by applicable law, regulation, contract, program, or facility requirements, the successful candidate must meet applicable U.S. citizenship, security clearance, export‑control, and/or facility‑access requirements.
Any citizenship or security‑clearance requirement will be based on the specific requirements of the position and applicable law.
The position requires regular presence in a manufacturing, construction, and industrial environment. The employee may be required to:
Stand and walk for extended periods.
Navigate manufacturing areas, construction areas, equipment platforms, and other industrial work environments.
Occasionally lift and carry materials or equipment weighing up to 30 pounds.
Bend, stoop, reach, climb stairs or ladders, and perform other physical activities reasonably associated with the position.
Wear required personal protective equipment (PPE).
Work in environments where exposure to manufacturing equipment, industrial noise, temperature variations, and other workplace conditions may occur.
Avio USA is committed to providing reasonable accommodations to qualified individuals with disabilities to enable them to perform the essential functions of the position, consistent with applicable law.
Avio USA is an Equal Opportunity Employer, including disability and protected veteran status.
All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, protected veteran status, or any other status protected by applicable federal, state, or local law.
Avio USA is committed to providing equal employment opportunities to qualified individuals with disabilities and protected veterans and to providing reasonable accommodations to qualified individuals with disabilities and disabled veterans in accordance with applicable law.
As a federal contractor or subcontractor, Avio USA complies with applicable requirements of Section 503 of the Rehabilitation Act of 1973, as amended, and the Vietnam Era Veterans' Readjustment Assistance Act (VEVRAA), as amended, including applicable nondiscrimination and affirmative action requirements.
Applicants who require a reasonable accommodation to participate in the application or employment process may contact Human Resources at humanresources@aviousa.com.
Equal Opportunity Employer, including disability and protected veteran status.
Flexible work from home options available.
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