Job Description
PDW Administration Huntsville, AL, USA Posted on May 9, 2026 Apply now Performance Drone Works (PDW) builds technologies for the warfighter, by the warfighter. Born out of the Drone Racing League, our roots are competitive, our mindset is tactical, and our mission is clear: deliver purpose-built unmanned systems to those who serve. We are not here to sell vapor; we build and ship real capabilities for real missions. As we scale production, we are seeking a Senior Director of Sustaining Manufacturing Engineering to lead the industrialization, launch, and continuous improvement of our drone platforms. This role will ensure our products are manufacturable, testable, reliable, and continuously improving as we scale volume and complexity. What You’ll Do Lead all sustaining and NPI manufacturing engineering deliverables and functions to support the transition from development to scalable production and ongoing optimization. Build and lead a multidisciplinary team spanning manufacturing, industrial, test, and equipment engineering, working in close partnership with the Manufacturing Systems & Automation team. Drive NPI manufacturing readiness for new sUAS platforms providing early DFX input to Core Engineering, and lean process development to ensure pilot production readiness including manufacturing specs, BOMs, workflow, work instructions, tools and fixtures, assembly & test equipment, training, and process validation. Define and support NPI stage gates through the PLC (Concept/ Pilot/ EVT/ DVT/ PVT/ GA/ EOL) including direct support of proto and pilot builds to ensure production quality, throughput, traceability, and cost targets are met. Partner with Core Engineering to incorporate DFX to eliminate design-driven manufacturing risks early, and own sustaining design improvements to reduce costs, improve high-volume production. Own production process yield, throughput, cycle times, labor efficiency, line optimization, cost, and manufacturability across multiple product lines. Lead continuous improvements to production per data analytics,6-sigma, and lean methods to ensure assembly and test capacity scales to meet demand. Drive improvements for safety / ergo, quality, yield, throughput, delivery, and cost by employing data-driven, lean methods. Drive tools, fixtures, jigs for new and existing processes, and collaborate with Manufacturing Systems and Automation to deploy assembly and inspection equipment for manual, and semi-automated and fully automated processes Support the development and own sustainment of functional sub-system and system tests for production. Drive MES selection, integration with ERP, QMS and PLM; including test equipment and data integration, data analytics, automated reporting, and training and deployment of augmented reality (AR) work instructions into production. Build capacity models, staffing plans, labor standards, throughput optimization, and ramp plans. Support new equipment selection, development, commissioning, and sustaining maintenance (TPM) through its lifecycle to ensure required OEE. Support domestic outsourcing & contract manufacturing by ensuring transfer readiness (docs, processes, equipment, standards, training, ongoing alignment). Build, and develop a data-driven, hands-on, and accountable team of manufacturing engineers, technicians, TPMs, and managers. Partner with cross-functionally to support NCR disposition, CAPA, compliance, product improvements, and drive operational excellence. Support Supply Chain and Quality for materials readiness, and supplier quality, and act as the technical bridge between product design and factory execution. Requirements Bachelor’s degree in Engineering (Mechanical, Electrical, Manufacturing, Aerospace) or applicable technical discipline. Master’s degree (MS/MBA) a plus. 15+ years of hands-on manufacturing engineering leadership experience in high-growth, high-volume manufacturing environments using Lean / Six Sigma methods. Proven track record leading NPI and scaling processes and tools to HV production; preferably in either sUAS, robotics, consumer electronics, or aerospace / defense. Strong experience developing assembly and test processes, complex system integration (HW+FW/SW), MES integration of test data and data analytics. Strong background in DFM/DFA/DFT, commissioning and sustaining semi-auto and automated production, and employing lean manufacturing. Seasoned in NPI readiness, process capability, employing Lean / Six Sigma methods to optimize yield, throughput, cycle time, labor efficiency, cost, and OEE. Experience integrating enterprise systems (MES, ERP, QMS, PLM, EAM/CMMS) for traceability, NCR, CAPA, genealogy