Sr Process Engineer

Valid8 Financial, Inc.; Littleton (CO); On-site; USD 110,000 - 135,000; Full time

Benefits offered by this job

Discretionary bonus

Paid time off (PTO)

Health benefits

Job summary

ExoTerra is seeking a skilled Process Engineer to lead the development, industrialization, and ramp-up of manufacturing processes for a new aerospace production facility. You will define end-to-end workflows, select equipment, and drive throughput while meeting AS9100 and quality requirements.

The ideal candidate has 5–10+ years in aerospace or regulated industries, with experience launching new lines, applying lean methods, and using PFMEA/SPC tools.

Qualifications

• Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, or related field.
• 5–10+ years in manufacturing/process engineering, preferably in aerospace or regulated industries.
• Proven experience launching new production lines or facilities.
• Strong knowledge of high-rate production environments and process scaling.
• Experience with lean manufacturing, Six Sigma, or continuous improvement methodologies.
• Familiarity with aerospace quality systems (AS9100, NADCAP).
• Experience with process validation, PFMEA, control plans, and statistical process control (SPC).

Responsibilities

• Lead the design, development, and implementation of manufacturing processes for a new aerospace production site.
• Define and document end-to-end production workflows, including material flow, tooling, equipment, and staffing models.
• Support facility layout planning to optimize throughput, ergonomics, and safety.
• Collaborate with cross-functional teams to ensure readiness for production ramp.
• Develop and validate manufacturing processes, work instructions, and standard operating procedures (SOPs).
• Design and implement process controls to ensure repeatability, quality, and compliance with aerospace standards (AS9100).
• Select and qualify equipment, tooling, and automation solutions.
• Conduct process capability studies (Cp, Cpk) and establish control plans.
• Lead production ramp-up efforts, achieving target rate, yield, and cost metrics.
• Identify and eliminate bottlenecks to ensure high-rate production throughput.
• Implement lean manufacturing techniques (takt time, line balancing, value stream mapping).
• Drive continuous improvement initiatives to enhance productivity and reduce waste.
• Ensure processes meet aerospace regulatory and quality requirements.
• Support First Article Inspection (FAI) and qualification builds.
• Partner with Quality teams to resolve non-conformances and root cause investigations.
• Implement error-proofing (poka-yoke) and robust quality controls.
• Develop and track KPIs such as yield, cycle time, and OEE.
• Utilize data analytics to identify improvement opportunities.
• Lead Six Sigma / root cause analysis initiatives to improve process stability.
• Work with Design Engineering, Supply Chain, Quality, Operations, and Facilities teams.
• Support supplier development and integration of external manufacturing partners.
• Provide technical leadership during design reviews and production readiness assessments.

Skills

Process engineering

Lean manufacturing

Six Sigma

Quality systems

Cross-functional collaboration

Education

Bachelor’s degree in Mechanical Engineering

Job description

ExoTerra is a world leader in solar electric propulsion systems and space exploration satellites. The company develops Hall Thrusters, propulsion modules, microsatellites and launchvehicleupper stages. We have been awarded multiple propulsion module and satellite contracts.

Position Summary

We are seeking a highly skilled and results-drivenProcess Engineerto lead the development, industrialization, and ramp-up of manufacturing processes for anew high-rate aerospace production facility. This role is critical in establishing robust, scalable,and efficient processes that meet stringent aerospace quality, cost, and delivery requirements.

The ideal candidate will have deep experience inmanufacturing process design, production ramp, and aerospace/precision manufacturing environments, with a strong focus on throughput optimization, quality assurance, and lean principles.

Essential Functions:

Facility & Process Setup

Lead the design, development, and implementation of manufacturing processes for a new aerospace production site.

Define and document end-to-end production workflows, including material flow, tooling, equipment, and staffing models.

Support facility layout planning to optimize throughput, ergonomics, and safety.

Collaborate with cross-functional teams to ensure readiness for production ramp.

Process Development & Industrialization

Develop and validate manufacturing processes, work instructions, and standard operating procedures (SOPs).

Design and implement processcontrols toensure repeatability, quality, and compliance with aerospace standards (e.g., AS9100).

Select and qualify equipment, tooling, and automation solutions.

Conduct process capability studies (Cp, Cpk) and establish control plans.

Production Ramp & High-Rate Manufacturing

Lead production ramp-up efforts, achieving target rate, yield, and cost metrics.

Identify and eliminate bottlenecks to ensure high-rate production throughput.

Implement lean manufacturing techniques (e.g., takt time, line balancing, value stream mapping).

Drive continuous improvement initiatives to enhance productivity and reduce waste.

Quality & Compliance

Ensure processes meet aerospace regulatory and quality requirements.

Support First Article Inspection (FAI) and qualification builds.

Partner with Quality teams to resolve non-conformances and root cause investigations.

Implement error-proofing (poka-yoke) and robust quality controls.

Data, Metrics, and Continuous Improvement

Develop and track key performance indicators (KPIs), such as yield, cycle time, and OEE.

Utilize data analytics to identify improvement opportunities.

Lead Six Sigma / root cause analysis initiatives to improve process stability.

Cross-Functional Collaboration

Work closely with Design Engineering, Supply Chain, Quality, Operations, and Facilities teams.

Support supplier development and integration of external manufacturing partners.

Provide technical leadership during design reviews and production readiness assessments.

BasicQualifications

Bachelor’s degree in Mechanical Engineering, Manufacturing Engineering, Industrial Engineering, or related field.

5–10+ years of experience in manufacturing/process engineering, preferably in aerospace or regulated industries.

Proven experience in launching new production lines or facilities.

Strong knowledge of high-rate production environments and process scaling.

Experience with lean manufacturing, Six Sigma, or continuous improvement methodologies.

Familiarity with aerospace quality systems (AS9100, NADCAP).

Experience with process validation, PFMEA, control plans, and statistical process control (SPC).

Preferred Qualifications

Excellent verbal and written communication skills

Experience with Spacecraft Fabrication and Test

Experience with non-conformance resolution

Experience with manufacturing process development

Experience with Programming

Export Control / Compliance Requirements

To conform to U.S. Government space technology export regulations, including the International Traffic in Arms Regulations (ITAR) you must be a U.S. citizen, lawful permanent resident of the U.S., protected individual as defined by 8 U.S.C. 1324b(a)(3), or eligible to obtain the required authorizations from the U.S. Department of State.

The good faith base salary range (OR hourly range) for this role is $110,000-$135,000 at the time of this posting. Where you fall within the ,range depends on your experience, skills, and location. This range reflects base salary only and does not include benefits or bonus/incentive. This range may be adjusted in the future.

ExoTerra offers a comprehensive, total compensation package, which includes competitive salary, a discretionary annual bonus plan, paid time off (PTO), a comprehensive health benefit package and various other benefits.When you join our team, you’re not just an employee; you become part of a dynamic community dedicated to innovation and excellence.

Equal Employment Opportunity Statement

ExoTerra is an Equal Opportunity Employer. Employment decisions are made without regard to race, color, religion, national or ethnic origin, sex, sexual orientation, gender identity or expression, age, disability, protected veteran status or other characteristics protected by law.