PURPOSE: The Manufacturing Engineer will drive and support new product introduction, process optimization, and continuous improvement initiatives in a dynamic aerospace and defense manufacturing environment. This role focuses on composites, lean methodologies, and cross-functional collaboration to ensure manufacturability, quality, and productivity for aircrew and groundcrew helmets. DUTIES/RESPONSIBILITIES: New Product Development
- Lead and support the transition of new ballistic and impact-resistant systems from design to production.
- Work with multidisciplinary teams to ensure design feasibility, tool development, and manufacturing readiness.
- Lead and participate in design reviews, process qualification, and support pre-production builds.
- Develop Standard Work Instructions, PFMEAs, control plans, and other process documentation.
Process Improvement and Optimization
- Analyze and improve legacy processes using Lean and Six Sigma tools to reduce cost, scrap, and cycle time.
- Lead root cause investigations and implement corrective actions for manufacturing and quality issues.
- Optimize floor layout, spatial utilization, and line balancing to meet Takt Time and throughput targets.
- Convert batch and queue systems to continuous flow manufacturing lines.
Technical & Cross-functional Support
- Provide technical support to manufacturing, purchasing, quality assurance, and production control.
- Support tooling design, fabrication, and equipment development for cost-effective production.
- Conduct experimental trials to evaluate new or modified processes and technologies.
- Interface with all levels of the organization to communicate findings, drive action, and deliver reports.
- Research and recommend new manufacturing technologies to increase capacity, reduce costs, and improve quality through automation, AI or any similar advancements in technology
Documentation & Reporting
- Maintain and update engineering documentation, BOMs, routings, and process standards.
- Support audits and compliance with industry standards and internal procedures.
- Assist in cost and capacity analysis and identify innovative solutions to manufacturing challenges.
Additional Requirements
- Flexible schedule to support production and critical project deadlines.
- Ability to lead or support assigned tasks and cross-functional initiatives.
Requirements EDUCATION AND/OR PROFESSIONAL LICENSE(s): Bachelor's Degree in Mechanical, Industrial, Manufacturing, or Aerospace Engineering (or related technical field) required; advanced degree preferred. EXPERIENCE: 1-5 years of experience in a manufacturing or integrated product development team environment, preferably in the aerospace/defense sector. Hands-on experience with composite materials, molding techniques, and secondary operations is strongly preferred. Proven experience developing manufacturing documentation (MCPs, SWIs, BOMs, Labor Routings). KNOWLEDGE, SKILLS AND ABILITIES • In-depth knowledge of composite manufacturing processes, tooling, and design for manufacturability. • Working knowledge of Lean, Six Sigma, DMAIC, Kaizen, and other continuous improvement methodologies; certification preferred. • Proficient in root cause analysis, PFMEA, SPC, GD&T, and process capability studies. • Proficient in SolidWorks (3D modeling), Microsoft Office Suite, Visio, Project, and statistical tools such as Minitab. • Strong written and verbal communication skills, with the ability to interact across all organizational levels. • Self-starter with strong organizational skills, able to handle multiple priorities and drive initiatives to completion. • Familiarity with AS9100 procedures and new product introduction stage gates preferred. POSITION SUPERVISES: Position will be primarily one of an individual contributor. May be required to supervise and coordinate activities with technicians or lab personnel and coordinate with engineers but will not be directly responsible for reporting/evaluating others. Candidate needs to take direction and work independently with minimal supervision. CONTACT WITH OTHERS: Requires close contact and interaction with other R&D staff, engineering, and production process personnel. Contact with vendors, customers and professional organizations is an essential part of the job. Contact with customers is important to understand their needs, communicate progress, and gauge status. PHYSICAL/MENTAL/COMMUNICATION REQUIREMENTS: Employee is occasionally required to stand; walk; sit; use hands to handle, or feel objects, tools, or controls; reach with hands and arms; climb stairs; balance; stoop, kneel, crouch, or crawl; talk or hear; and taste or smell. The employee may lift and/or move up to 50 lbs. Specific vision abilities required by the job may include close vision, distance vision, color vision, peripheral vision, depth perception, and the ability to adjust focus. The individual must have a high level of comprehension, and a high level of general, verbal, written, and numerical intelligence. WORK ENVIRONMENT: Works majority of the day in a climate-controlled environment, with the exception of or otherwise specified, performing work in the warehouse or manufacturing areas which are subject to changes in temperature and/or noise. TRAVEL: Limited travel required LOCATION: Gentex's Carbondale facility is located in Northeastern Pennsylvania in Lackawanna County. Carbondale, PA is about twenty miles north of Scranton, PA, 50 miles south of Binghamton, NY, and about 125 miles from New York City and Philadelphia. The area hosts numerous nearby state parks, nature preserves and local colleges and universities, including The University of Scranton and Marywood University. Northeast Pennsylvania is a beautiful area and offers an excellent cost of living. It is a great place to work, recreate, meet people, raise a family and live! Gentex Corporation is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard for any applicable state or federal protected class. Gentex is an E-Verify Participant. Pre-employment drug/alcohol/background screening is required.
