Sr. Process Engineer

PROMETHEUS ENERGETICS, LLC; Bloomington (IN); On-site; USD 120,000 - 180,000; Full time

Benefits offered by this job

Medical, dental, and vision insurance

Life and AD&D insurance

Disability insurance

401(k) savings plan

Paid time off and company holidays

Job summary

Prometheus Energetics, LLC in Bloomington, IN is seeking an experienced Sr. Process Engineer to lead manufacturing processes for solid rocket motor production, from design handoff to shop-floor execution.

You will own SWIs, equipment integration, and process validation, collaborating with Engineering, Operations, Quality, and EHS to meet safety, quality, and customer performance requirements. This role demands a strong background in aerospace/defense manufacturing and continuous improvement

Qualifications

• Bachelor's degree in Mechanical, Aerospace or Manufacturing Engineering or related field.
• 6+ years of progressive manufacturing, process, or tooling engineering in aerospace/defense hardware.
• Proficiency with 3D CAD and PDM/PLM systems (Windchill).
• Strong knowledge of GD&T per ASME Y14.5 and precision metal fabrication.
• Experience generating routers, PFMEAs, and detailed work instructions.
• Excellent written, verbal, analytical, and executive communication skills.
• U.S. citizenship and ability to obtain a U.S. Government Secret Security Clearance.

Responsibilities

• Establish, prove out, and sustain manufacturing processes, SWIs, and routing for SRM cast/cure and assembly.
• Analyze flows, ergonomics, and line balance to optimize throughput and scale production.
• Serve as primary manufacturing engineering contact for shop-floor operators with real-time guidance.
• Define capital equipment specs, evaluate proposals, and manage full lifecycle integration.
• Lead on-site equipment installation, proof loading, and line buy-off.
• Lead RCCA investigations and drive Lean/Six Sigma improvements using PFMEA and SPC.

Skills

Analytical skills

Written and verbal communication

Executive communication

Education

Bachelor's degree in Mechanical Engineering or related

Tools

Windchill PDM/PLM

3D CAD software

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 Sr. 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 toolingProcess- 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

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.

Work Environment & Physical Requirements

• Work is performed in office, machine shop, laboratory, and energetics manufacturing environments, including high-hazard areas subject to enhanced safety and security controls.
• Must be able to wear required personal protective equipment (PPE) and comply with site safety, explosive-safety, electrostatic discharge (ESD), and access-control requirements.
• Ability to move throughout a manufacturing site, inspect physical tooling, participate in shop-floor audits, and occasionally lift up to 25 pounds.
• Regular, reliable attendance is required. Periodic travel to vendor machine shops, secondary company facilities, or customer sites may be required during startup, tool qualification, or critical production events.

Benefits

• Medical, dental, and vision insurance
• Life and AD&D insurance; short- and long-term disability coverage
• 401(k) savings plan
• Paid time off and company holidays