Staff Engineer, Advanced Manufacturing - Special Projects (R4972)

Shield AI; Seattle, Northern (WA, KY); Hybrid; USD 150,000 - 230,000; Full time

Job summary

Shield AI in the Seattle area is seeking a Staff Advanced Manufacturing Engineer to own critical production processes for a next‑generation jet program. You will deploy capital equipment, oversee factory-scale production, and mentor engineers across cross‑functional teams.

The role emphasizes throughput improvements, cost reductions, and robust production systems, with opportunities to work on MES/QMS tools, lean methodologies, and advanced manufacturing technologies.

Qualifications

• Top Secret clearance required.
• 7+ years of experience in manufacturing engineering, production systems, process development, or assembly engineering.
• Bachelor’s degree in Mechanical, Industrial, Mechatronics, or related STEM field.
• Prototype manufacturing experience in startup/rapid-growth environments.
• Strong understanding of machining, composites, avionics and/or assembly.
• Able to work in a fast-paced, high-pressure environment and adapt to changing priorities.

Responsibilities

• Define the Bill of Process and manufacturing sequence for subassemblies or cells.
• Map MBOM to operations, tooling needs, and process controls.
• Build ergonomic workstations with proper tools and PPE.
• Create operator-ready Work Instructions with torque specs and inspection points.
• Conduct time studies and lead kaizen improvements.
• Establish standardized work, visual controls, and audit systems; iterate with operators.
• Capture defects and tool feedback to drive root cause and corrective actions.
• Partner with Quality on in-process checks and FAI readiness.
• Implement ECOs and maintain work instructions.

Skills

Leadership

Cross-functional collaboration

Problem solving

Adaptability

Education

Bachelor’s degree in Mechanical, Industrial, Mechatronics, or related STEM field

Tools

MES/QMS systems

Torque analyzers

Minitab

Excel

DOE

PFMEA

Control Plans

Job description

Shield AI is a venture-backed defense-tech company with the mission of protecting service members and civilians with intelligent systems. Its products include Hivemind autonomy software, V-BAT and X-BATaircraft, and Aechelon simulation and synthetic reality technologies. With offices and facilities across the U.S., Europe, the Middle East, and Asia-Pacific, Shield AI’s technology actively supports operations worldwide. For more information, visit www.shield.ai. Follow Shield AI on LinkedIn, X, Instagram, and YouTube.

Job Description:

The Staff Advance Manufacturing Engineer, you’ll take ownership of critical manufacturing processes across multiple programs, leading initiatives to increase throughput, reduce costs, and scale our operations. You’ll be instrumental in building out the infrastructure for a new production line supporting a next-generation jet, including selecting and deploying capital equipment, implementing hardware and software tools, and establishing robust production systems. Working across engineering, supply chain, and production, you’ll ensure smooth integration of new technologies and provide mentorship to other engineers. This role is ideal for someone who thrives on cross-functional impact, technical leadership, and factory-scale execution

What you'll do:

• Define the Bill of Process and manufacturing sequence for assigned subassemblies or cells.
• Map MBOM to operations, tooling needs, and process controls.
• Build ergonomic workstations (height/reach zones, shadow boards, calibrated torque tools, ESD controls, POU materials).
• Create visual, operator-ready Work Instructions with torque specs, PPE, inspection points, and MES revision control.
• Conduct time studies, compute takt/CT, identify bottlenecks, and lead kaizen improvements.
• Establish standardized work, visual controls, job aids, and layered audit systems; iterate with operators.
• Capture shop-floor lessons learned defects, build issues, tooling feedback and drive root cause and corrective action.
• Partner with Quality on in-process checks, error-proofing, and FAI readiness.
• Implement ECOs, validate process updates, and maintain work instructions accordingly.
• Tools & Skills: MES/QMS systems, torque analyzers, Minitab/Excel (SPC, capability, DOE), lean/5S, PFMEA, ergonomic assessment tools, Control Plans, Standard Operating Procedures.

Required qualifications:

• Currently hold a Top Secret clearance required
• 7+ years of experience in manufacturing engineering, production systems, process development, or assembly engineering.
• Bachelor’s degree in Mechanical, Industrial, Mechatronics, or related STEM field.
• Experience in prototype manufacturing in a startup or rapid-growth environment.
• Strong understanding of manufacturing processes, including machining, composites, avionics and/or assembly.
• Demonstrated ability to work in a fast-paced, high-pressure environment and adapt to changing priorities.

Preferred qualifications:

• Knowledge of quality standards such as AS9100 or ISO 9001.
• Proficiency in CAD software
• Familiarity with advanced manufacturing technologies, such as additive manufacturing or automation systems.
• Hands-on experience with manufacturing equipment and tooling design.Strong project management skills, including experience managing multiple priorities and deadlines.

$150,000 - $230,000 a year

* Compensation for this role is based on the position’s work location. The salary range shown reflects the listed location and may vary if the position is based in a different geographic market. Actual compensation will also consider factors such as experience, skills, qualifications, and internal equity.

Full-time regular employee offer package:

Pay within range listed + Bonus + Benefits + Equity

Temporary employee offer package:

Pay within range listed above + temporary benefits package (applicable after 60 days of employment)

Salary compensation is influenced by a wide array of factors including but not limited to skill set, level of experience, licenses and certifications, and specific work location.

All offers are contingent on a cleared background and possible reference check. Military fellows and part-time employees are not eligible for benefits.

Shield AI is proud to be an equal opportunity workplace and is an affirmative action employer. We are committed toequal employment opportunity regardless of race, color, ancestry, religion, sex, national origin, sexual orientation, age, marital status, disability, gender identity or Veteran status. If you have a disability or special need that requires accommodation, please let us know.