Senior Mechanical Manufacturing Engineer

SAIC is seeking an experienced Senior Mechanical Manufacturing Engineer to lead the design, development, optimization, and scaling of manufacturing processes for mechanical products and assemblies. This role bridges product engineering and operations, ensuring designs are robust, cost-effective, manufacturable, and capable of meeting quality, safety, delivery, and production-volume requirements. This role is onsite in Huntsville, AL in both office and manufacturing-floor environments. The role may require occasional travel to supplier sites, contract manufacturers, or other company locations. Appropriate personal protective equipment may be required when working in production areas.

The ideal candidate combines strong mechanical engineering fundamentals with deep hands-on expertise in machining, fabrication, assembly, tooling, process validation, and continuous improvement within a manufacturing environment.

Key Responsibilities:

• Lead the development, implementation, and optimization of manufacturing processes for mechanical components, subassemblies, and finished products.
• Partner with product design and R&D teams to ensure designs meet Design for Manufacturing and Assembly (DFMA) principles from concept through production release.
• Develop manufacturing work instructions, process flow diagrams, standard operating procedures, routings, bills of materials, and technical documentation.
• Design, specify, and validate production tooling, fixtures, gauges, test equipment, and automated or semi-automated assembly systems.
• Evaluate and improve machining, welding, sheet-metal fabrication, casting, molding, coating, assembly, and inspection processes, as applicable.
• Support new product introduction activities, including prototype builds, pilot production, process qualification, first-article inspection, and production ramp-up.
• Conduct manufacturing feasibility reviews and identify risks related to tolerances, materials, assembly sequence, ergonomics, equipment capacity, quality, and cost.
• Investigate process failures, nonconformances, scrap, rework, yield losses, and customer-return issues; lead root-cause analysis and corrective/preventive actions.
• Apply Lean manufacturing, Six Sigma, statistical process control, and continuous-improvement methodologies to improve throughput, quality, safety, and cost performance.
• Establish and monitor key process metrics, such as cycle time, first-pass yield, overall equipment effectiveness, scrap rate, labor efficiency, and manufacturing cost.
• Collaborate with Quality, Supply Chain, Production, Maintenance, and external suppliers to resolve manufacturing and supplier-related technical issues.
• Support supplier selection, qualification, process audits, and capability assessments for externally manufactured components and assemblies.
• Develop capital-equipment justifications, define equipment requirements, support vendor selection, and oversee equipment installation and acceptance.
• Mentor junior engineers and technicians and provide technical leadership across cross-functional manufacturing projects.
• Ensure manufacturing processes comply with applicable safety, quality, environmental, and regulatory requirements.