As a Senior Quality Engineer at Zipline, you will design and scale multiple in-house final assembly lines for aircraft, zips, docks, and critical feeder sub-assemblies. You will ensure these lines meet growing demand while driving down cost and elevating product quality. Your first major project involves building a new manufacturing line to bring in-house a complex electro-mechanical sub-assembly. You will collaborate cross-functionally with design, quality, and operations teams, and provide technical mentorship to junior engineers.

Responsibilities

Develop and optimize manufacturing processes and documentation for complex electro-mechanical assemblies, from prototype builds to full-scale production.
Lead planning, budgeting, design, procurement, & commissioning of Assembly Lines and associated facilities & equipment at Zipline for Product Builds
Lead process validation and verification activities, including PFMEAs, capability studies, first article inspections, and pilot builds.
Collaborate closely with design engineers to drive design-for-manufacturability (DFM), ensuring product designs are optimized for reliable and cost-effective assembly.
Own tooling and fixture development, from concept through fabrication, installation, and validation, to support scalable and repeatable manufacturing.
Identify and implement continuous improvement initiatives to improve quality, reduce cycle time, and lower production costs (e.g., lean manufacturing, automation, poka-yoke).
Troubleshoot and resolve production issues, working cross-functionally with quality, design, and maintenance teams to implement corrective and preventive actions.
Support ramp-up of new products and manufacturing lines, coordinating cross-functional activities to ensure smooth transitions from development to production.
Track and analyze manufacturing performance metrics, including first-pass yield, throughput, downtime, and cost of poor quality, to drive data-informed decisions.
Provide technical mentorship to junior manufacturing engineers and technicians, sharing best practices and reviewing designs and process approaches

Requirements

7+ years of experience designing and developing manufacturing lines - proven track record of scaling something from the 10s of products per month to the 1000s of products per month
Design for Manufacturability (DFM/DFA): Strong understanding of how to influence product design for cost-effective, scalable, and reliable assembly.
Hands-on experience working with products that combine mechanical systems, electronics, and software integration.
Fixture and tooling design: Experience designing and validating custom fixtures, jigs, and tools to support repeatable, ergonomic, and efficient processes.
Manufacturing process validation: Deep knowledge of PFMEA, control plans, process capability (Cp/Cpk), and statistical process control (SPC).
Proficiency in 3D CAD Software (Siemens NX preferred)
Proficient in writing SOPs, work instructions, and process flow documents.
Familiar with statistical tools (e.g., Minitab, JMP, Excel) for analyzing yield, process capability, and production trends.
MES/ERP systems: Experience with manufacturing execution systems and resource planning software to manage production data and operations.
Skilled at identifying root causes and rapidly implementing sustainable corrective actions in a fast-paced environment.
Proven ability to work with design, quality, supply chain, and operations teams to deliver manufacturing outcomes.
Comfortable guiding and reviewing work of junior engineers and technicians.
Strong written and verbal communication skills for documenting processes, presenting data, and aligning teams.
Demonstrated ability to manage complex projects with minimal oversight—from planning through execution and sustainment.
Worked in a super fast-paced environment that is in a constant state of evolution.

Nice to have

NX is your primary CAD tool
Experience working with multiple different MES systems and transition to internally built MES system
End of Line Test Development Experience - wrote and scoped test plans, executed tests, analyzed data