Position Title: Manufacturing Engineer II – Energetics & CAD/PAD
Salary Range: $85,000 – $105,000 / year
Locations: Fairfield, NJ & Byram, NJ (On-site / Multi-facility travel)
Employment Type: Full-Time
Company Overview
We design, develop, and manufacture mission-critical energetic, pyrotechnic, Cartridge Actuated Devices (CAD), and Propellant Actuated Devices (PAD). Our products serve high-consequence applications across aerospace, defense, government, and commercial sectors where ultra-high reliability, precision manufacturing, and strict process repeatability are mandatory.
Role Summary
The Production Engineer II bridges the gap between design engineering and shop-floor execution. This role is responsible for planning, establishing, and optimizing manufacturing and assembly processes for energetic hardware, custom tooling, and precision-machined components. Working under general direction, the Production Engineer leads Design for Manufacturability (DFM) transitions, designs machine shop fixturing, develops work instructions (routers/SOPs), resolves manufacturing non-conformances (MRB), and drives continuous process improvements within an AS9100 / ISO 9001 quality framework.
Key Responsibilities
- Manufacturing Process Planning & Routing: Establish, maintain, and optimize manufacturing bills of materials (MBOMs), assembly routers, standard operating procedures (SOPs), and detailed shop floor work instructions.
- Tooling & Fixture Engineering: Design and implement custom assembly tooling, machine shop fixtures, energetic loading aids, and inspection gages to enhance manufacturing throughput and operator safety.
- New Product Introduction (NPI) & DFM: Partner with Design Engineering during PDR/CDRs to ensure robust Design for Manufacturability (DFM) and Design for Assembly (DFA), executing smooth handoffs from R&D into production.
- Discrepancy Resolution & MRB: Act as engineering authority on the Material Review Board (MRB); disposition non-conforming hardware, perform root-cause failure analyses (8D, 5-Why, Fishbone), and implement Corrective and Preventive Actions (CAPA).
- Process Capability & Risk Mitigation: Conduct Process Failure Mode and Effects Analyses (PFMEA) and implement Statistical Process Control (SPC) to minimize variance and eliminate assembly risks in energetic operations.
- Machine Shop & Assembly Floor Support: Provide day-to-day technical support to machine shop machinists, assembly technicians, and pyrotechnic handling teams to resolve production bottlenecks and machining/assembly challenges.
- Quality & Cybersecurity Standards: Maintain strict adherence to AS9100 / ISO 9001 quality management systems, NIST SP 800-171 / CMMC Controlled Unclassified Information (CUI) safeguarding protocols, and ATF energetic handling regulations.
Required Qualifications
Education: Bachelor's degree in Manufacturing Engineering, Industrial Engineering, Mechanical Engineering, Materials Science, or a related discipline.
Experience: 3–5+ years of production, manufacturing, or process engineering experience in precision aerospace, defense, ordnance/energetics, medical device, or high-reliability electromechanical manufacturing.
Technical Skills: Proficiency in reading and interpreting complex engineering drawings using ASME Y14.5 GD&T.Experience designing assembly jigs, machining fixtures, or inspection tooling using 3D CAD (SolidWorks preferred).Strong working knowledge of conventional and CNC machining, metal finishing/plating, and precision mechanical assembly methods.
Quality & Systems:
- Practical experience with ERP/MRP systems (e.g., SAP, SyteLine, Epicor, Sage) for routings, BOMs, and engineering change implementation.
- Working knowledge of AS9100 / ISO 9001 quality management systems and structured root-cause problem-solving (8D, CAPA).
Legal & Regulatory Requirements:
- Must be a U.S. Person (U.S. Citizen or Permanent Resident) to satisfy ITAR and EAR requirements.Must be able to obtain and maintain an ATF Employee Possessor status.
Desired Skills & Experience
- Machine Shop Proficiency: Hands-on machine shop skills (manual lathe, mill, tooling setup) to evaluate and troubleshoot machining processes directly on the floor.
- Energetics Handling: Prior experience with pyrotechnic loading, explosive presses, hermetic sealing, or hazardous material safety standards (DoD 4145.26-M, OSHA).
- Lean / Continuous Improvement: Practical experience with Lean Manufacturing principles (5S, Value Stream Mapping, Kaizen, SMED, Line Balancing) or Six Sigma Green Belt.
- CUI / Defense Compliance: Prior training or exposure to Controlled Unclassified Information (CUI) handling procedures under NIST 800-171 / DFARS.
Work Environment & Physical Demands
- Active, hands-on environment split between the manufacturing production floor, machine shop, energetic loading/assembly cells, and office engineering spaces.
- Routine local travel between our Fairfield, NJ and Byram, NJ facilities (must possess a valid driver's license).
- Physical activity includes walking, standing for extended periods on the manufacturing floor, bending, reaching, and occasionally lifting up to 40 lbs of tooling, fixtures, or raw materials.
